KNF UN 828, Translation Of Original Operating And Installation Instructions

Page 1: ...38 TRANSLATION OF ORIGINAL OPERATING AND INSTALLATION INSTRUCTIONS MINI DIAPHRAGM VACUUM PUMPS Note Before operating the pump and the accessories please read the operating instructions and pay attention to the safety precautions ...

Page 2: ... 4 Technical Data 9 5 Design and function 13 6 Installation and connection 18 7 Operation 32 8 Servicing 39 9 Troubleshooting 51 10 Spare parts and accessories 54 11 Returns 55 KNF Inc 2 Black Forest Rd Trenton NJ 08691 Phone 1 609 890 8600 http www knf com ...

Page 3: ...ssible 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 conse quences are specified here Danger levels Signal word Meaning Consequences if not observed DANGER warns of immedi ate danger Death or serious injuries and or serious damage are the conse quence WARNING warns of possible dang...

Page 4: ...nst rain splash hose and drip water as well as other pollutions 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 trans ferred danger free in the specific applicat...

Page 5: ...logical substances The pumps are not suitable for transferring fuel The pumps are not suitable for transferring explosive and combus tible materials The pumps are not suitable for transferring fibers The pumps are not suitable for transferring oxidizing agent The pumps are not suitable for transferring foodstuffs The pumps are not suitable for use with aggressive media Other pumps in the KNF produ...

Page 6: ...ork Make sure that the personnel has read and understood the Operat ing and Installation Instructions and in particular the Safety chap ter Observe the accident prevention and safety regulations when per forming any work on the pump and during operation Ensure that the pump is separated from the mains and is de ener gized The pump heads heat up during operation avoid contact with them Make sure th...

Page 7: ...ional and interna tional 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 com missioned until such time as it has been determined that the ma chine in which the partly completed machine...

Page 8: ... KNDC B UN 838 1 2 KN 29DC B DIN EN 55014 1 2 DIN EN 55014 1 2 DIN EN 61000 6 2 3 DIN EN 61000 3 2 3 DIN EN 60034 1 DIN EN 50581 DIN EN 60335 1 DIN EN 61000 6 1 2 DIN EN 50581 DIN EN 50581 Tab 2 The pump is maintenance free But KNF recommends checking the pump regularly with regard to conspicuous changes in noise and vibrations Only have repairs to the pumps carried out by the KNF Customer Service...

Page 9: ...n 28 34 42 Tab 4 Liters in standard state 1013 mbar Pumps with DC motor Parameter UN 828 ANDC UN 828 KNDC UN 838 ANDC UN 838 KNDC Max permissible operating pressure bar g psig 1 0 14 5 0 5 7 3 Ultimate vacuum mbar abs 100 100 Flow rate at atm pressure l min 27 32 Tab 5 Liters in standard state 1013 mbar Pumps with brushless DC motor Parameter UN 828 KNDC B UN 828 KN 29DC B UN 838 KNDC B UN 838 KN ...

Page 10: ... Pumps with brushless DC motor Parameter UN 828 KNDC B UN 828 KN 29DC B UN 838 KNDC B UN 838 KN 29DC B UN 838 1 2 KNDC B UN 838 1 2 KN 29DC B Voltage V 24 24 24 Control voltage only 29 version V 0 1 5 0 1 5 0 1 5 Max operating current A for p patm for p patm 2 4 2 0 2 4 2 2 4 2 3 9 Starting current The starting current can be up to 50 above the maximum operating current Starting ramp ms 800 800 80...

Page 11: ...NDC B UN 838 1 2 KN 29 DC B The pump is protected against overheating by a temperature sensor on the motor board and equipped with overcurrent pro tection If one of these safety functions is triggered or if the maximum blocking time of the rotor is exceeded due to a fault the pump will be shut down and must be manually reset as follows Separate pump from the mains Remove the cause s of the fault b...

Page 12: ...29DC B UN 838 KNDC B UN 838 KN 29DC B UN 838 1 2 KNDC B UN 838 1 2 KN 29DC B ca 152 x 116 x 79 5 9 x 4 5 x 3 1 ca 152 x 118 x 79 5 9 x 4 6 x 3 1 ca 153 x 122 x 84 6 0 x 4 8 x 3 3 ca 243 x 129 x 95 9 5 x 5 0 x 3 7 ca 150 x 119 x 79 5 9 x 4 6 x 3 1 ca 150 x 123 x 82 5 9 x 4 8 x 3 2 ca 138 x 125 x 115 5 4 x 4 9 x 4 5 ca 137 x 129 x 115 5 3 x 5 0 x 4 5 ca 198 x 128 x 115 7 7 x 5 0 x 4 5 Maximum permis...

Page 13: ... Instructions English KNF 121249 121517 09 19 13 5 Design and function Design UN 828 _NI Fig 1 Design UN 828 _NI Design UN 838 _NI Fig 2 Design UN 838 _NI 1 Outlet pressure side 2 Inlet suction side 3 Electrical connection 4 Motor 1 Outlet pressure side 2 Inlet suction side 3 Electrical connection 4 Motor ...

Page 14: ...tallation Instructions English KNF 121249 121517 09 19 Design UN 838 1 2 KNI Fig 3 Design UN 838 1 2 KNI Design UN 828 _NDC Fig 4 Design UN 828 _NDC 1 Pneumatic connection 2 Motor 3 Electrical connection 4 Outlet pressure side 5 Inlet suction side 1 Outlet pressure side 2 Inlet suction side 3 Motor ...

Page 15: ... Instructions English KNF 121249 121517 09 19 15 Design UN 838 _NDC Fig 5 Design UN 838 _NDC Design UN 828 KNDC B and UN 828 KN 29DC B Fig 6 Design UN 828 KNDC B and UN 828 KN 29DC B 1 Outlet pressure side 2 Inlet suction side 3 Motor 1 Outlet pressure side 2 Inlet suction side 3 Motor controller 4 Motor ...

Page 16: ...ign UN 838 KNDC B and UN 838 KN 29DC B Fig 7 Design UN 838 KNDC B and UN 838 KN 29DC B Design UN 838 1 2 KNDC B and UN 838 1 2 KN 29DC B Fig 8 Design UN 838 1 2 KNDC B and UN 838 1 2 KN 29DC B 1 Outlet pressure side 2 Inlet suction side 3 Motor controller 4 Motor 1 Outlet pressure side 2 Inlet suction side 3 Motor 4 Motor controller 5 Pneumatic connection ...

Page 17: ...s and vapors The elastic diaphragm 4 is moved up and down by the eccentric 5 and the connection 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 1 Outlet valve 2 Inlet valve...

Page 18: ...ical Data Observe the safety precautions see Chapter 3 6 1 Installation of the pump Choose a safe location flat surface for the pump Before installation store the pump at the installation location to bring it up to ambient temperature For mounting dimensions see Fig 10 UN 828 _NI Fig 11 UN 838 _NI Fig 12 UN 838 1 2 KNI Fig 13 UN 828 _NDC Fig 14 UN 838 _NDC Fig 15 UN 828 KNDC B and UN 828 KN 29DC B...

Page 19: ...ons English KNF 121249 121517 09 19 19 Fig 10 Mounting dimensions UN 828 _NI All dimensional tolerances con form to DIN ISO 2768 1 Tolerance Class V only N 828 KNE Fig 11 Mounting dimensions UN 838 _NI All dimensional tolerances con form to DIN ISO 2768 1 Tolerance Class V 1 8 NPT 1 8 NPT G 1 8 or 1 8 NPT G 1 8 or 1 8 NPT ...

Page 20: ...ons English KNF 121249 121517 09 19 Fig 12 Mounting dimensions UN 838 1 2 KNE All dimensional tolerances conform to DIN ISO 2768 1 Tolerance Class V Fig 13 Mounting dimensions UN 828 _NDC All dimensional tolerances conform to DIN ISO 2768 1 Tolerance Class V G 1 8 or 1 8 NPT G 1 8 or 1 8 NPT G 1 8 or 1 8 NPT G 1 8 or 1 8 NPT ...

Page 21: ...517 09 19 21 Fig 14 Mounting dimensions UN 838 _NDC All dimensional tolerances conform to DIN ISO 2768 1 Tolerance Class V Fig 15 Mounting dimensions UN 828 KNDC B and UN 828 KN 29DC B All dimensional tolerances conform to DIN ISO 2768 1 Tolerance Class V Connection X only for UN 828 KN 29DC B G 1 8 or 1 8 NPT G 1 8 or 1 8 NPT G 1 8 or 1 8 NPT 2X 2 ...

Page 22: ...ions UN 838 KNDC B and UN 838 KN 29DC B All dimensional tolerances conform to DIN ISO 2768 1 Tolerance Class V Connection X only for UN 838 KN 29DC B Fig 17 Mounting dimensions UN 838 1 2 KNDC B and UN 838 1 2 KN 29DC B All dimensional tolerances conform to DIN ISO 2768 1 Tolerance Class V Connection X only for UN 838 1 2 KN 29DC B G 1 8 or 1 8 NPT G 1 8 or 1 8 NPT G 1 8 or 1 8 NPT ...

Page 23: ...nd drip water as well as other pollutions Make sure that the installation location is accessible for maintenance and service The IP protection class of the pump motor is indicated on the pump label 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 against grease and oils Protect the pump from vibra...

Page 24: ...rom the electrical supply For pumps with AC motor The motors of the pump must be protected according to EN 60204 1 protection against excess current or overload ing For max operating current of the pump see pump s type plate For pumps with DC motor The pumps may only be operated in a SELV power circuit It is recommended that an additional Emergency Stop switch is installed The pump must be install...

Page 25: ...ctromagnetic HF filed pulse modulated Discharging of static electricity High frequency asymmetric Fast transients were not carried out cause the products do not contain electronic modules which can be affected by these tests The Surge test can only be passed with additional means or is not mandatory if From EN 61000 6 1 technical norm for EMC protec tion part 1 10 test demands for EMC protection t...

Page 26: ...the pump label 2 Electrical connect of the pump according to Tab 12 page 27 UN 8__ K_DC B and Tab 13 page 28 UN 8__ K_ 29DC B Note the proper polarity see marking on the motor Incorrect lead connection will damage electronics of brushless DC mo tors type designation ending with B The supply wires have inverse polarity protection in the motor board for this purpose while the control voltage wires d...

Page 27: ...sh KNF 121249 121517 09 19 27 UN 8__ K_DC B Fig 18 Connection plan motor electronics UN 8__ K_DC B Motor Nominal voltage V 24 Voltage range V 7 30 Electrical connection Lead assignment Function Lead color Signal Name Size Supply voltage red U AWG 18 Ground 0V black U GND AWG 18 Tab 12 Connection plan motor electronics UN 8__ K_DC B ...

Page 28: ...r Signal name Size Supply voltage red U AWG 18 Ground 0V black U GND AWG 18 5V power supply black U5V AWG 28 UL 20932 Input signal speed control white UCtrl AWG 28 UL 20932 Output signal speed yellow USpd AWG 28 UL 20932 Input signal Remote ON OFF green URmt AWG 28 UL 20932 Output signal fault purple UFlt AWG 28 UL20932 Ground grey blue orange GND AWG 28 UL 20932 5V Power supply U5V Control voltag...

Page 29: ...w max pump max flow min max 2 100 Input impedance 1kHz kΩ 12 Output signal speed USpd Analog Pulses per revolution 1 Pulse duty cycle 50 1 PWM Signal PWM frequency Hz 50 0 5 Output level high V 5 4 1 V5V Output level low V 0 0 0 6 Max current carrying capacity mA 10 Output impedance 1 kHz kΩ 9 Input signal Remote ON OFF URmt Input level high motor ON V 5 3 9 5 5 Input level low motor OFF V 0 0 0 9...

Page 30: ...sed as voltage source and at the same time as the default control voltage for the white wire the output voltage decreases when the voltage source is under load At the same time the default voltage for the white wire de creases Because of this the nominal final speed can no longer be reached Fig 20 Exposition Control without Potentiometer Fig 21 Exposition Control with Potentiometer ...

Page 31: ...Technical Data If the pump s 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 Confusion between suction and pressure sides can lead to breakage of connected components on the suction and pres sure sides 1 Remove the protective plugs from the hose connection threads 2 The accessories silence...

Page 32: ...ke 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 WARNING Hazard of the pump head bursting due to excessive pressure increase Do not exceed max permissible operatin...

Page 33: ... handling saturated or nearly saturated vapors 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 For pumps with AC motor The pump may not start up against pressure or vacuum during switch on This also applies in operating following a brief power failure If a pump starts against pressure or vacuum it ...

Page 34: ... is specified via the control voltage 7 2 1 1 Speed input 29 versions The speed range of nmin nmax is shown scaled to the control volt age UCtrl UCtrl min 0 1 V UCtrl max 5 0 V If the control voltage is less than UCtrl min the motor is OFF Fig 22 Control voltage speed curve standard Speed is specified through the 8 pin controller connection white wire see Tab 13 Optional analog settings for contro...

Page 35: ...er generates speed synchronized pulse width modulation see Fig 24 Fig 24 Analog speed output standard Optional speed output The motor controller generates a speed synchronized right angle frequency with 5V TTL level see Fig 25 Fig 25 Digital speed output optional 7 2 2 Remote ON OFF 29 versions Remote ON OFF is through an 8 pin controller connection green wire see Tab 13 To start the motor the gre...

Page 36: ... Connection communication plug see Fig 19 PIN 1 do not connect PIN 2 do not connect PIN 3 GND PIN 4 5V max 50 mA PIN 5 TX MBLC PIN 6 RX MBLC Motor connection options external control unit Fig 26 External activation options optional The following motor functions can be controlled Motor remote ON OFF In the factory condition the motor is OFF when operating voltage is applied However as an option the...

Page 37: ...acters When transmitting the commands must be followed by ASCII character CR carriage return deci mal value 013 The underlined expressions are not characters but symbols as explained in table Tab 16 Parameter Command Function Reply Motor dB Start S E dE Stop S E Speed dSnnnn nnnn speed value Set nominal speed ns E Tab 14 Control commands A pause of at least 25 ms is required after the dB instructi...

Page 38: ...motor speed Value min 1 nl Minimum nominal motor speed Value min 1 nh Maximum nominal motor speed Value min 1 ii Operating current of the motor Value mA ti Temperature of the motor controller Value C ei Fault status 16 bit value Tab 16 Symbols The symbols represent the ASCII codes of sequences of digits any length The controller processes input values only as whole num bers integers Interface leve...

Page 39: ...flush it with air or with inert gas if required for safety reasons under atmospheric conditions ambient pressure for about five minutes 8 2 2 Cleaning pump Pump disconnected from mains and de energized WARNING Dangerous substances in the pump can cause a health hazard Depending on the substance transferred caustic burns or poisoning are possible Wear protective clothing if necessary e g pro tectiv...

Page 40: ...gs and diaphragm at the same time If the diaphragm and the valve plates sealings are not changed at the same time the nominal performance of the pump is not guaranteed after the servicing WARNING Dangerous substances in the pump can cause a health hazard Depending on the substance transferred caustic burns or poisoning are possible Wear protective clothing if necessary e g pro tective gloves Flush...

Page 41: ...re reference is made to turning or holding the cooling fan the necessary operations must be carried out by turning or holding the counterweight 10 b Remove pump head 1 Mark the position of the head plate 3 intermediate plate 2 and housing 1 relative to each other by a drawing line M with a felt tip marker This helps avoid incorrect assembly later 2 Undo the 4 screws 4 in the head plate and lift th...

Page 42: ...ove the valve plates sealings 6 from the intermediate plate 3 Check that the valve seats in the head plate and intermediate plate are clean if scratches distortion or corrosion are evident on these parts they should be replaced 4 Lay the new valve plates sealings 6 in the recesses in the in termediate plate 2 The valve plates sealings for suction and pressure sides are identical as are upper and l...

Page 43: ...lates sealings are the only parts of the pump subject to wear They are simple to change Always change valve plates sealings and diaphragm at the same time In the case of models with two pump heads service both heads at the same time If the diaphragm and the valve plates sealings are not changed at the same time the nominal per formance of the pump is not guaranteed after the servicing WARNING Dang...

Page 44: ...of electrical power Make sure the pump is voltage free and secure it 2 Only for models with DC motors no cooling fan Remove cover 5 from pump housing after loosening the four screws On these models which have no fan where reference is made to turning or holding the cooling fan the necessary operations must be carried out by turning or holding the counterweight Fig 29 One headed pump UN 828 KNI Leg...

Page 45: ...n until the connecting rod connecting part between motor shaft and diaphragm is at top dead center 7 Screw the new diaphragm 7 complete with diaphragm spacer s 8 into the connecting rod clockwise and tighten it by hand d Change valve plates sealings 1 Use a small screwdriver to remove the two screw caps 10 on the pump head and then undo the screw s 9 2 Separate the head plate 3 from intermediate p...

Page 46: ...aphragm 8 to top dead center 2 Place the pump head consisting of intermediate plate 2 with valve plates sealings 6 and head plate 3 on the housing in the position indicated by the marking M 3 Gently tighten the screws 4 evenly and diagonally 4 Turn the fan to check that the pump rotates freely 5 Turn the fan again to bring the diaphragm to top dead center 6 Now tighten screws 4 firmly torque 3 5 N...

Page 47: ...oth heads at the same time If the diaphragm and the valve plates sealings are not changed at the same time the nominal per formance of the pump is not guaranteed after the servicing WARNING Dangerous substances in the pump can cause a health hazard Depending on the substance transferred caustic burns or poisoning are possible Wear protective clothing if necessary e g pro tective gloves Flush the p...

Page 48: ... carried out by turning or holding the counterweight b Remove pump head 1 Mark the position of the head plate 3 intermediate plate 2 and housing 5 relative to each other by a drawing line with a felt tip marker M see Fig 31 This helps avoid incorrect as sembly later 2 Undo the 4 screws 4 in the head plate 3 and lift the head plate with the intermediate plate off the pump housing For two headed pum...

Page 49: ...plates sealings 1 Use a small screwdriver to undo the screw 9 2 Separate the head plate 3 from intermediate plate 2 3 Remove the valve plates sealings 6 from the intermediate plate 4 Check that the valve seats in the head plate and intermediate plate are clean if scratches or distortion corrosion are evident on these parts they should be replaced 5 Lay the new valve plates sealings 6 in the recess...

Page 50: ...gm 8 to top dead center 2 Place the pump head s consisting of intermediate plate 2 with valve plates sealings 6 and head plate 3 on the hous ing in the position indicated by the marking M 3 Gently tighten the screws 4 evenly and diagonally 4 Turn the fan to check that the pump rotates freely 5 Turn the fan again to bring the diaphragm to top dead center 6 Now tighten screws 4 firmly torque 3 5 Nm ...

Page 51: ... and remove the cause of the overcurrent for ex ample improper pressure liquid in the pump heads The pump must be separated from the mains for several seconds before the electronics will permit restarting For pumps with brushless DC motor Wrong polarity of the connec tion wires Separate pump from the mains Be aware of right polarity of the connection wires and con nect pump For pumps with AC motor...

Page 52: ...tion of pneumatic hoses or connectors too narrow or restricted Disconnect the pump from the system and determine output values Remove restriction e g valve if necessary If applicable use larger diameter hoses or connectors Leaks in connections hoses or pump head Make sure the hoses are properly seated on the hose con nectors Replace leaking hoses Eliminate leaks Connections or hoses com pletely or...

Page 53: ...be programmed so that the er ror output voltage exhibits the same characteristics as the LED With factory settings only 1 or 0 are logically outputted as voltage at the fault output Fig 35 LED blinking duration according to different faults To delete the error condition the motor has to be disconnected from the mains Fault cannot be rectified If you are unable to identify the cause of the problem ...

Page 54: ...ragm 4x valve plates sealings 4x O rings Spare parts kit for pump type Order No UN 828 043824 UN 838 043825 UN 838 1 2 313749 Tab 24 10 2 BLDC Options Description Order No PWM analog voltage converter Function Smoothing of the speed output signal into an analog voltage output and simul taneous transformation of 5V to 5V On request External potentiometer for setting of the speed On request RS232 Le...

Page 55: ...ctions English KNF 121249 121517 09 19 55 11 Returns Prior authorization is required to return a pump to KNF Please go to www knf com and fill out the form in our Service Repairs Service Repair at KNF page After the form is submit ted KNF will contact you with an authorization number to ship against ...

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