KNF UNPK09 Bedienungsanleitung

Operating and Installation Instructions

Swing Piston

Compressors and

Vacuum Pumps

Type Range: UNPK09 UNPK09.1

UNPK09DC UNPK09.2

UNPK09.1.2

Fig. 1: UNPK09 Fig. 2: UNPK09.1.2

You have selected a high-quality KNF product; the following tips will help you operate it safely and reliably

over a long period of time. Carefully study the Operating and Installation Instructions before using the

pumps and observe at all times the relevant instructions to avoid dangerous situations. The manual was

produced for the serial pumps stated above. With customer-specified projects (pump types starting with

“PU“ or “MPU“) there could be differences in detail. For customer-specified projects please therefore take

into account any agreed technical specifications, as well as these instructions.

List of Contents Page

1. Description, Operating Conditions........................................... 2

2. Safety...................................................................................... 3

3. Installation............................................................................... 4

4. Operation................................................................................ 5

5. Servicing................................................................................. 6

6. Cleaning................................................................................ 10

7. Trouble Shooting................................................................... 11

8. Spare parts ........................................................................... 12

9. Accessories........................................................................... 12

10. Tables................................................................................... 13

11. Product Return.......................................................................14

KNF Neuberger, Inc

2 Black Forest Rd

Trenton, NJ 08691-1810

Phone: 609-890-8600

Fax: 609-890-8323

www.knf.com/usa.htm

Ident#121576-125598

Revision (09/12)

Description, Operating Conditions Swing Piston Pumps NPK 09

1. Description, Operating Conditions

KNF pumps in the NPK range transfer, evacuate and compress

oil-free. In operation they are maintenance-free. The noise levels

from the pumps are ca. 60 dB (A) (one head model, with hose

connectors and inlet filter fitted).

1.1. Electrical Equipment

See the motor-plate for full electrical data.

The protection class of standard version is IP00.

The ac-motors used are fitted as standard with a thermal switch to

protect against overloading.

1.2. Operating Conditions

Handling air at temperatures between + 5 °C …+ 40 °C.

KNF swing piston compressors and vacuum pumps must not be

used for liquids. You will find suitable liquid pumps in our Product

Program.

For maximum permissible operating pressure, ultimate vacuum,

and flow capacity see section 10.

The KNF swing piston compressors and vacuum pumps must not

be used in areas where there is a danger of explosion.

If your potential application lies outside the above limits discuss it

with our technical adviser (see last page for contact telephone

number).

1.3. Ambient Conditions

When the pump is operating the following ambient conditions must

be maintained:

Ambient temperature during operation: between

+ 5 °C …+ 40 °C.

The pumps must be protected from the effects of dust and

water.

During operation an adequate supply of air for cooling

must be provided.

The pumps must not be used in areas where there is a

danger of explosion.

Swing Piston Pumps NPK 09 Safety

2. Safety

The standard pumps have Protection Class 00, and so offer no

protection against contact or foreign bodies. It is therefore

essential to provide protection for persons against contact

with live parts (e.g. electrical connections, motor windings),

and moving parts (e.g. fan). Protection against the entry of

foreign bodies must also be provided.

The pump has no protection against water. In this case too, as

far as is relevant, measures to protect the pump must be taken

before putting it into service.

Note that the pumps may only be used for their intended purpose.

The pumps must not be used in areas where there is a danger of

explosion.

Components connected to the pump must be designed to

withstand the pneumatic performance of the pump.

Take care that safety regulations are observed when connecting

the pump to the electricity supply.

For pumps with a thermal switch: when the operation of the pump

is interrupted by the thermal switch, the pump will re-start auto-

matically after cooling down. Take all care necessary to prevent

this leading to a dangerous situation.

Use only original KNF spare parts.

Pumps in the NPK 09 range conform to the safety regulations of

the EC Low Voltage Directive 2006/95/EC, and of the EC Directive

2004/108/EC concerning Electromagnetic Compatibility.

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 essential requirements of Annex I of

Directive 2006/42/EC (general principles) are applied and

observed.

The pumps conform to the EC Directive 2004/108/EC concerning

Electromagnetic Compatibility.

The following harmonized standards have been used:

UNPK09 DC UNPK09 AC

DIN EN 55014-1/2 DIN EN 55014-1/2

DIN EN 60034-1 DIN EN 61000-3-2/3

DIN EN 60335-1

Tab. 1

EC Directives / Standards

Installation Swing Piston Pumps NPK 09

3. Installation

Pumps in the NPK 09 range are OEM models intended for

installation in equipment. When installing them make certain

that accident prevention regulations, and safety instructions,

including those for subsequent operation are observed. The

safety instructions in section 2 must be observed.

The dimensions of the mountings are given in Data Sheet E 300.

Install the pump so that the fan can draw in sufficient cooling air.

Install the pump so as accidental finger contact is with the fan is

impossible.

Fit the pump at the highest point in the system, so that condensate

cannot collect in the head of the pump - that prolongs working life.

When making the electrical installation the safety regulations

must be observed. In particular make sure that the electricity

supply is isolated before trying to connect the pump.

Compare the supply data with the data on the motor-plate. The

voltage must not vary by more than +10% and -10% from that

shown on the type-plate.

The earth (ground) wire must be connected to the motor (not

necessary on dc motors up to 24 V).

For brushed dc motor lead wires connection:

•Red: V+

•Black: Ground

ÎIncorrect lead wire connection will damage motor.

For brushless dc motor lead wire connection:

•Red: V+

•Black: Ground

•White: Voltage control 0-5 V DC (4 wire motor only)

•Green: Frequency output (4 wire motor only)

ÎIncorrect lead wire connection will damage motor.

In the electrical installation, arrangements (complying with EN

60335-1) must be made for disconnecting the pump motor from the

electrical supply.

The pump must be installed so that contact with live parts

(connection, possibly windings) is impossible.

We recommend that a fuse is installed in the supply circuit; the

operating current is given in Data Sheet E 300.

Remove the protection plugs from the port threads.

The accessories silencer/filter and hose connectors (where

applicable) are screwed into the port threads.

Connect the suction and pressure lines.

Arrange the suction and pressure lines so that condensate cannot

run into the pump.

Mechanical

Electrical

Caution:

Pneumatic

Swing Piston Pumps NPK 09 Operation

4. Operation

The pump must not start against pressure or vacuum. When it is

switched on the pressure in the suction and pressure lines must be

atmospheric. This also applies when the pump restarts after the

power has been cut off for a short period.

The maximum permissible operating pressure (see section 10)

must not be exceeded.

To prevent the maximum permissible operating pressure being

exceeded, restriction or control of the air or gas flow should only be

carried out in the suction line.

If restriction or control of the air or gas flow is made on the pres-

sure side ensure that the maximum permissible operating pressure

is not exceeded.

When the pump is at a standstill the inlet and exhaust must be at

normal atmospheric pressure.

Change the filter (accessories) if it is dirty.

The piston seals, and to a lesser extent the valve plates are the

only parts of the pump subject to wear. Wear is usually indicated

by a drastic reduction in the pneumatic performance. When

replacing parts proceed as described in section 5.

Ambient conditions: see section 1.3.

Servicing Swing Piston Pumps NPK 09

5. Servicing

Before working on the pump, isolate the power supply

securely, then check that the lines are not live.

The piston seal, and to a lesser extent the valve plates are the only

parts of the pump subject to wear. They are simple to change.

When changing the piston seal, check the valve plates for damage

(tongues bent, corrosion).

The position numbers in the following text refer to figs. 3 to 6.

Fig. 3:

Pump element (single head types)

Fig. 4:

Pump element (twin head types)

Fig. 5:

Pump element (all types)

Fig. 6:

Pump head (all types)

Specifiaction

Pos. Description

1 Housing

2 Intermediate plate

3 Ribbed head

4 Screw

5 Connection

(only twin head

models)

6 Gasket

7 Valve Plate

8 Valve Plate

9 O-Ring

10 Cylinder

11 Retainer Plate

12 Support

13 Piston seal

14 Screw

15 Washer(s)

16 Connecting rod

17 Counter weight

18 Cover

MMark

KCompression symbol

Swing Piston Pumps NPK 09 Servicing

5.1. Changing the piston seal

Spare part* Quantity

Piston seal 1 (twin head pumps: 2)

Countersunk flat head screw (14) 2 (twin head pumps: 2)

Tab. 2 * According to Spare parts list, section 8

Tools/Material

Philips screwdriver no. 2

Screwdriver (blade width 5,5 mm)

Phillips screwdriver no. 1

Felt-tip pen

Tab. 3

In the case of twin head pumps both piston seals should always be

changed at the same time.

Dismantling

1. In the case of twin head models the connecting pipework

between the heads must first be removed.

2. Make a mark (M) on the ribbed head (3), intermediate plate (2),

and housing (1) with a felt-tip pen (see M in figures 3 and 4).

This helps avoid incorrect assembly later.

3. Unscrew the 4 screws (4) and take off the ribbed head (3).

4. Remove gasket (6), valve plate (7), intermediate plate (2) and

valve plate (8) from housing (1).

5. Only for the pump model NPK09 DC: Take off the cover (18)

after removing the 4 screws securing it.

For this pump type applies: Where reference is made to turning

or holding the cooling fan, the necessary operations must be

carried out by turning or holding the counter-weight (17).

6. Turn the fan to bring the retainer plate (11) to top dead center.

7. Pull the cylinder (10) upwards to remove it.

8. Hold the fan, loosen the retainer plate screw (14) and remove

screw, retainer plate, support (12) and washer(s) (16).

9. Remove the piston seal (13) from the retainer plate.

10. Check that all parts are free from dirt and clean them if

necessary (see section 6.Cleaning).

11. Check the valve plates for damage (tongues bent, corrosion); if

necessary use new ones when reassembling.

Assembly

1. Hold the connecting rod (16) vertical, and replace the cylinder

(10) on the pump housing (1).

Parts required

Tools required

Servicing Swing Piston Pumps NPK 09

2. Re-assemble the "piston assembly":

Lay the new piston seal (13) on the retainer plate (11) with

the sealing lip towards the free surface of the retainer

plate.

Lay the support (12) on the retainer plate/piston seal

assembly.

Push the new countersunk flat head screw (14) through the

assembly, and fit the same number of washers as previ-

ously used.

3. Insert the piston assembly (retainer plate, support, piston seal

and washer(s) with their screw) into the cylinder from above,

on to the connecting rod.

The piston seal must not be distorted during assembly. It must

make contact with the cylinder all round its circumference.

4. Fasten the "piston assembly" by tightening the screw (14).

5. Reassemble the "head assembly": stack the following parts on

top of each other in the order given: ribbed head (3), gasket

(6), valve plate (7), intermediate plate (2), and valve plate (8).

Fig. 6 shows the correct orientation of the parts, particularly the

valve plates, in relation to the compression symbol on the head

plate. Both valve plates are identical, and they can be fitted

either way up. The intermediate plate can also be fitted either

way up.

6. Place the "head assembly" on the pump housing (1) - as a

guide to orientation see fig. 3 (single head models) or fig. 4

(twin head models). Reference point is the compression

symbol (indicated with a Kin the diagrams), or the mark (M).

7. Tighten the screws (4) at first lightly, then firmly by hand, in a

diagonal pattern (max. tightening torque 1.5 Nm).

8. Rotate the fan by hand to check that pump turns easily.

9. Pump model NPK 09 DC only: refit cover (18) to the housing.

For twin head pumps, repeat the operations described for the

second head, and replace the connections between the two heads.

If, after changing the piston seal, the specified vacuum is not

reached, check the following:

pneumatic connections for tightness

for twin head models that the head connections are

gas-tight

if the washer(s) under the support has/have been

assembled.

If, after changing the piston seal, the pump produces no flow,

check the position and orientation of gasket (6), valve plate (7),

intermediate plate (2) and valve plate (8). See fig. 3,4 and 6.

5.2. Changing the valve plates

Spare part* Quantity

Valve plates 2 (twin head pumps: 4)

Parts required

Swing Piston Pumps NPK 09 Servicing

Tab. 4 * According to Spare parts list, section 8

Tools/Material

Philips screwdriver no. 2

Felt-tip pen

Tab. 5

In the case of twin head pumps, both valve plates must always be

changed at the same time. The text below describes the operations

necessary for one head.

To change the valve plates, the following operations of Section 5.1

Changing the piston seal must be carried out:

Disassembly

1 to 4, 10 and 11.

Assembly

5 to 8 using new valve plates (2 for each head).

For twin head pumps, repeat the operations described for the

second head, and replace the connections between the two heads.

If, after changing the valve plates, the specified vacuum is not

reached, check the following:

pneumatic connections for tightness

for twin head models that the head connections are

gas-tight

If, after changing the valve plates, the pump produces no flow:

check the position and orientation of gasket (6), valve plate

(7), intermediate plate (2) and valve plate (8). See fig. 3, 4

and 6.

If you have any questions about servicing call our technical adviser

(see last page for contact telephone number).

Tools required

Cleaning Swing Piston Pumps NPK 09

6. Cleaning

When changing valve plates and diaphragm, inspect all parts for

dirt before assembling the pump head, and clean them if

necessary.

As far as possible, clean the parts with a dry cloth. Solvents should

not be used as they can attack the plastics, and synthetic rubber

parts. If a compressed air line is available, blow the parts out with

it.

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