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Diaphragm Vacuum Pump N 828 / N 838

Servicing

Translation of original Operating and Installation Instructions, english, KNF 121249-121517 09/19

8. Servicing

8.1. Servicing schedule

Component

Servicing interval

Pump

Regular inspection for external dam-
age or leaks

Hose connections

Regular inspection for external dam-
age or leaks

Diaphragm and valve
plates

Replace when pumping capacity
decreases, or sooner

Silencer (accessory)

Change if it is dirty

Tab. 18

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 (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-

tective gloves.

➔

Take the proper steps to clean the pump.

CAUTION

Danger of burns from hot pump parts

The pump head or motor may be hot even after the

pump has been shut off.

➔

Allow the pump to cool off after operation.

➔

Solvent should be used for cleaning only if the head materials

are not corroded (ensure compatibility of the material).

➔

If compressed air is available, blow out the parts.

Requirements

Summary of Contents for N 828

Page 1: ...838 TRANSLATION OF ORIGINAL OPERATING AND INSTALLATION INSTRUCTIONS ENGLISH 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: ...sign 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 Neuberger GmbH Alter Weg 3 79112 Freiburg Germany Phone 49 0 7664 5909 0 Fax 49 0 7664 5909 99 E mail info knf de www knf de ...

Page 3: ...sible 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 dange...

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: ... work 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 energized The pump heads heat up during operation avoid contact with them Make sure t...

Page 7: ...nal and inter national 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 i...

Page 8: ...C B N 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 resp...

Page 9: ...low rate at atm pressure l min 28 34 42 Tab 4 Liters in standard state 1013 mbar Pumps with DC motor Parameter Value N 828 ANDC N 828 KNDC Value N 838 ANDC N 838 KNDC Max permissible operating pressure bar g 1 0 0 5 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 Value N 828 KNDC B N 828 KN 29DC...

Page 10: ... Maximum permissible mains voltage fluctuations 10 Tab 8 Pumps with brushless DC motor Parameter Value N 828 KNDC B N 828 KN 29DC B Value N 838 KNDC B N 838 KN 29DC B Value N 838 1 2 KNDC B N 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 t...

Page 11: ...28 KN 29DC B N 838 KNDC B N 838 KN 29DC B N 838 1 2 KNDC B N 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 p...

Page 12: ... ANE N 828 KNE N 838 _NE N 838 1 2 KNE N 828 _NDC N 838 _NDC N 828 KNDC B N 828 KN 29DC B N 838 KNDC B N 838 KN 29DC B N 838 1 2 KNDC B N 838 1 2 KN 29DC B ca 152 x 115 5 x 79 ca 152 x 118 x 79 ca 153 x 122 x 84 ca 243 x 129 x 95 ca 150 x 119 x 79 ca 150 x 123 x 82 ca 138 x 125 x 115 ca 137 x 129 x 115 ca 198 x 128 x 115 Maximum permissible ambient relative humidity 80 for temperatures up to 31 C ...

Page 13: ...on Instructions english KNF 121249 121517 09 19 13 5 Design and function Design N 828 _NE Fig 1 Design N 828 _NE Design N 838 _NE Fig 2 Design N 838 _NE 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: ...nstallation Instructions english KNF 121249 121517 09 19 Design N 838 1 2 KNE Fig 3 Design N 838 1 2 KNE Design N 828 _NDC Fig 4 Design N 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: ...ion Instructions english KNF 121249 121517 09 19 15 Design N 838 _NDC Fig 5 Design N 838 _NDC Design N 828 KNDC B and N 828 KN 29DC B Fig 6 Design N 828 KNDC B and N 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: ... Design N 838 KNDC B and N 838 KN 29DC B Fig 7 Design N 838 KNDC B and N 838 KN 29DC B Design N 838 1 2 KNDC B and N 838 1 2 KN 29DC B Fig 8 Design N 838 1 2 KNDC B and N 838 1 2 KN 20DC 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: ...Technical 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 N 828 _NE Fig 11 N 838 _NE Fig 12 N 838 1 2 KNE Fig 13 N 828 _NDC Fig 14 N 838 _NDC Fig 15 N 828 KNDC B and N 828 KN 29DC B F...

Page 19: ... and Installation Instructions english KNF 121249 121517 09 19 19 Fig 10 Mounting dimensions N 828 _NE All dimensional tolerances conform to DIN ISO 2768 1 Tolerance Class V only N 828 KNE Fig 11 Mounting dimensions N 838 _NE All dimensional tolerances conform to DIN ISO 2768 1 Tolerance Class V ...

Page 20: ...perating and Installation Instructions english KNF 121249 121517 09 19 Fig 12 Mounting dimensions N 838 1 2 KNE All dimensional tolerances conform to DIN ISO 2768 1 Tolerance Class V Fig 13 Mounting dimensions N 828 _NDC All dimensional tolerances conform to DIN ISO 2768 1 Tolerance Class V ...

Page 21: ...uctions english KNF 121249 121517 09 19 21 Fig 14 Mounting dimensions N 838 _NDC All dimensional tolerances conform to DIN ISO 2768 1 Tolerance Class V Fig 15 Mounting dimensions N 828 KNDC B and N 828 KN 20DC B All dimensional tolerances conform to DIN ISO 2768 1 Tolerance Class V Connection X only for N 828 KN 29DC B ...

Page 22: ... 09 19 Fig 16 Mounting dimensions N 838 KNDC B and N 838 KN 29DC B All dimensional tolerances conform to DIN ISO 2768 1 Tolerance Class V Connection X only for N 838 KN 29DC B Fig 17 Mounting dimensions N 838 1 2 KNDC B and N 838 1 2 KN 29DC B All dimensional tolerances conform to DIN ISO 2768 1 Tolerance Class V Connection X only for N 838 1 2 KN 29DC B ...

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 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 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: ...ectromagnetic 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 ...

Page 26: ... the type plate 2 Electrical connect of the pump according to Tab 12 page 27 N 8__ K_DC B and Tab 13 page 28 N 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 do...

Page 27: ...ectronics N 8__ K_DC B Motor Nennspannung Nominal voltage V 24 Spannungsbereich Voltage range V 7 30 Elektrische Anschlüsse Electrical connection Litzenbelegung lead assignment Funktion function Litzenfarbe lead color Signalname signal name Größe size Speisespannung Supply voltage rot red U AWG 18 Speisespannung 0V Ground 0V schwarz black U GND AWG 18 Tab 12 Connection plan motor electronics N 8__...

Page 28: ... GND AWG 18 5V Ausgangsspannung 5V power supply schwarz black U5V AWG 28 UL 20932 Eingangssignal Drehzahlregelung Input signal speed control weiß white UCtrl AWG 28 UL 20932 Ausgangssignal Drehzahl Output signal speed gelb yellow USpd AWG 28 UL 20932 Eingangssignal Remote EIN AUS Input signal Remote ON OFF grün green URmt AWG 28 UL 20932 Ausgangssignal Fehler Output signal fault lila purple UFlt A...

Page 29: ...cycle range 0 100 Tastgradbeschreibung min Pumpe min Förderleistung max Pumpe max Förderleistung Duty cycle description min pump min flow max pump max flow min max 2 100 Eingangsimpedanz 1kHz Input impedance 1kHz kΩ 12 Ausgangssignal Drehzahl USpd Output signal speed USpd Analog Pulse pro Umdrehung Pulses per revolution 1 Pulstastverhältnis Pulse duty cycle 50 1 PWM Signal PWM Frequenz PWM frequen...

Page 30: ...belastbarkeit Max current carrying capacity mA 10 Ausgangsimpedanz 1kHz Output impedance 1kHz kΩ 9 Tab 13 part 3 Connection plan motor electronics N 8__ K_ 29DC B If the black wire is used 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...

Page 31: ...echnical Da ta 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: ...rm it up before 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 pressur...

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 tecti...

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: ...ere 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 t...

Page 42: ...move 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 intermediate 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 performance of the pump is not guaranteed after the servicing WARNING Dange...

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 N 828 KNE Lege...

Page 45: ...n until the connecting rod connecting part between motor shaft and diaphragm is at top dead centre 7 Screw the new diaphragm 7 complete with diaphragm spac er 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 ...

Page 46: ...aphragm 8 to top dead centre 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 centre 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 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 the pu...

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 pump...

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 reces...

Page 50: ...gm 8 to top dead centre 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 centre 6 Now tighten screws 4 firmly torque 3 5 Nm ...

Page 51: ...e and remove the cause of the overcurrent for example 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 connection 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 complete ly or...

Page 53: ...be programmed so that the error 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 p...

Page 54: ...ab 24 10 2 Accessories General accessories Description Order No Silencer G 1 8 007006 Hose connector straight for all pump types except N 838 1 2 KN_ PA G 1 8 ID 6 000360 Hose connector for N 838 1 2 KN_ PA G 1 8 ID 8 004975 Tab 25 General for pumps with brushless DC motor Description Order No PWM analog voltage converter Function Smoothing of the speed output signal into an analog voltage output ...

Page 55: ...ns Prerequisite for repairing a pump by KNF is a completed Decon tamination Form This is made available on the KNF website as a download To find the form select your country on the overview page www knf com You can find the Decontamination Form in the download area If you have questions please contact your sales partner contact data see www knf com ...

Page 56: ...KNF worldwide Find your local KNF partner on www knf com ...

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