KNF NPK 04 DC, NPK 04 DCB Operating And Installation Instructions

Swing Piston Compressors and Vacuum Pumps

NPK 04 DC Pressure NPK 04 DC Vacuum

NPK 04 DCB Pressure NPK 04 DCB Vacuum

Operating and
Installation
Instructions

Read and observe these Oper­ating and Installation Instruc­tions!

KNF Micro AG
Zelglimatte 1b
CH-6260 Reiden
Switzerland
Phone [phone]
Fax [phone]
E-mail: [e-mail]
www.knf-micro.ch

Contents Page

1. About this document ................................................................. 2

2. Use ........................................................................................... 3

3. Safety ....................................................................................... 4

4. Technical Data ......................................................................... 6

5. Installation and connection ....................................................... 7

6. Operation .................................................................................. 9

7. Troubleshooting ...................................................................... 10

8. Accessory ............................................................................... 11

9. Returns ................................................................................... 12

10. Health and safety clearance and decontamination form ........ 13

KNF 121571-121574 06/14
Translation of original Operating and Installation Instructions, english Keep for future use!

About this document Swing Piston Pumps NPK 04

warning are specified here. The signal word, e.g.

1. About this document

1.1. Using the Operating and Installation Instruc­tions

The Operating and Installation Instructions are part of the pump.

 Pass on the Operating and Installation Instructions to the next

owner.

Project pumps

Customer-specific project pumps (pump models which begin with
"PJ" or "PM") may differ from the Operating and Installation In­structions.

 For project pumps, also observe the agreed upon specifica-

tions.

1.2. Symbols and markings

Warning

A danger warning is located here.

Possible consequences of a failure to observe the

WARNING

Danger levels

Signal word Meaning Consequences if not observed

DANGER

WARNING

CAUTION

Tab. 1

Other information and symbols

Warning, indicates the danger level.

 Measures for avoiding the danger and its conse-

quences are specified here.

warns of immedi­ate danger

warns of possible
danger

warns of a possibly
dangerous situa­tion

Death or serious injuries
and/or serious damage are the
consequence.

Death or serious injuries
and/or serious damage are
possible.

Minor injuries or damage are
possible.

2 Translation of original Operating and Installation Instructions, english, KNF 121571-121574 06/14

 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.

Swing Piston Pumps NPK 04 Use

tially

2. Use

2.1. Proper use

The pumps are designed for pumping air.

Owner's responsibility

Operating parameters and

conditions

Requirements for

transferred medium

Only install and operate the pumps under the operating parameters
and conditions described in Chapter 4, Technical data.

Only complete pumps may be taken into service.

Make sure that the installation location is dry and the pump is
protected against rain, splash, hose and drip water.

When using a medium other than air: Before using a medium,
check whether the medium can be transferred danger-free in the
specific application case.

Before using a medium, check the compatibility of the materials of
the pump head, swing piston and piston seal with the medium.

2.2. Improper use

Hazard of explosion when the surrounding atmos­phere is explosive

 The pumps may not be operated in an explosive

WARNING

WARNING

atmosphere.

Hazard of explosion from combustible and poten
explosive media

 The pumps may not be used to pump combus-

tible or potentially explosive media.

The pumps are not suitable for transferring dusts.

The pumps are not suitable for pumping vapors or liquids.

An overpressure must not be applied to the suction side of the
pump.

Translation of original Operating and Installation Instructions, english, KNF 121571-121574 06/14 3

Safety Swing Piston Pumps NPK 04

3. Safety

Note the safety precautions in sections 5. Installation and
connection, and 6. Operation.

The pumps are built according to the generally recognized rules of
technology and in accordance with the occupational safety and
accident prevention regulations. Nevertheless, dangers can result
during its use which lead to injuries to the user or others, or to
damage to the pump or other property.

Only use the pumps in proper technical condition and in accord­ance with its intended use in a safety and danger-conscious man­ner while observing the Operating and Installation Instructions.

Personnel

Working in a safety-

conscious manner

Handling dangerous media

Environmental protection

EC Directives / Standards

Make sure that only trained and instructed personnel or specially
trained personnel work on the pump. This especially applies to
assembly, connection and servicing work.

Make sure that the personnel has read and understood the Operat­ing and Installation Instructions, and in particular the "Safety"
chapter.

Observe the accident prevention and safety regulations when
performing any work on the pump and during operation.

When transferring dangerous media, observe the safety regula­tions when handling these media.

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.

For the purposes of the Machinery Directive 2006/42/EC, pumps
are “partly completed machinery,” and are therefore to be regarded
as not ready for use. Partly completed machinery may not be
commissioned until such time as it has been determined that the
machine in which the partly completed machinery is to be
assembled is in conformity with the provisions of the Machinery
Directive 2006/42/EC. The following essential requirements of
Annex I of Directive 2006/42/EC (general principles) are applied
and observed:

− General Principles No. 1

− No. 1.1.2. / 1.1.3. / 1.3.1. / 1.3.3. / 1.3.4. / 1.4.1. / 1.5.8. /

1.5.9. / 1.7.4. / 1.7.4.1. / 1.7.4.3.

As these partly completed machinery are OEM-models the power
supplies and the equipment for disconnecting and switching-off the
partly completed machinery respectively have to be considered
when mounting as well as over-current and overload protective
gear.

In addition a protection against mechanical parts in motion and hot
parts, if existing, has to be provided when mounting.

The pumps conform to the Directive 2011/65/EU (RoHS2).

4 Translation of original Operating and Installation Instructions, english, KNF 121571-121574 06/14

Swing Piston Pumps NPK 04 Safety

The pumps conform to the EC Directive 2004/108/EC concerning
Electromagnetic Compatibility.

The following harmonized standards have been used:

NPK 04 DC NPK 04 DCB
DIN EN 55014-1/2 DIN EN 55014-1

DIN EN 61000-6-2

Tab. 2

Customer service and

repairs

Only have repairs to the pump carried out by the KNF Customer
Service responsible.

Translation of original Operating and Installation Instructions, english, KNF 121571-121574 06/14 5

Technical Data Swing Piston Pumps NPK 04

4. Technical Data

Pump materials

Assembly Material
Head plate; cylinder PPS
Valve plate FPM
Piston seal PTFE
O-ring EPDM
Retainer plate Aluminium

Tab. 3

Pneumatic values

NPK 04 DC Vacuum

NPK 04 DCB Vacuum

Parameter Value
Max. permissible operating pressure [bar g] ­Ultimate vacuum [mbar abs.] 300
Delivery rate at atm. pressure [l/min]* 3.3

Tab. 4 *Liters in standard state (1,013 mbar)

NPK 04 DC Pressure

NPK 04 DCB Pressure

Parameter Value
Max. permissible operating pressure [bar g] 1.0
Ultimate vacuum [mbar abs.] ­Delivery rate at atm. pressure [l/min]* 3.3

Tab. 5 *Liters in standard state (1,013 mbar)

Electrical data

Parameter Value
Electrical data See type plate

Tab. 6

Other parameters

Parameter Values
Permissible

ambient temperature

+ 5 °C bis + 40 °C

Permissible media temperature + 5 °C to + 40 °C
Gas-tightness The gas-tightness of the pump

is dependent on the medium
used.*

Tab. 7

* If you have questions about this, please contact your KNF advi-

sor.

6 Translation of original Operating and Installation Instructions, english, KNF 121571-121574 06/14

Swing Piston Pumps NPK 04 Installation and connection

Only have the pump connected by an authorized

10% from

5. Installation and connection

Only install and operate the pump under the operating parameters
and conditions described in Chapter 4, Technical data.

Observe the safety precautions (see Chapter 3).

5.1. Installation

 Before installation, store the pump at the installation location to

bring it up to room temperature.

Mounting dimensions

Installation location

 See the data sheet for the mounting dimensions.

 Make sure that the installation location is dry and the pump is

protected against rain, splash, hose and drip water.

 Install the pump at the highest point in the system to prevent

condensate from collecting in the pump head.

 Protect the pump from dust.

 Protect the pump from vibrations and jolts.

5.2. Electrical connection

Extreme danger from electrical shock


specialist.

DANGER

 In the electrical installation, arrangements (complying with EN

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

Connecting pump

 Only have the pump connected when the power

supply is disconnected.

1. Compare the supply data with the data on the motor-plate. For
operating current see type plate.

The voltage must not vary by more than + 10% and ­that shown on the type-plate.

2. Connect the plus and minus pole.

With DC motors, note the proper polarity:
red motor cable: +
black motor cable: -

EMC-compatible Installation (brushless DC motor)

In order to remove the electrical interference according to EN
55014-1:1993 + A1:1997 all pumps with brushless DC motor (DC
B) must be equipped with an additional electronic circuit. This
electronic circuit has to be installed as close to the motor as possi­ble.

The additional circuitry is not necessary if a voltage supply has a
suppression of > 20 dB at 150 kHz and 0 dB at 1 MHz.

Translation of original Operating and Installation Instructions, english, KNF 121571-121574 06/14 7

Installation and connection Swing Piston Pumps NPK 04

The supplemental circuit must be structured according to the
following electrical diagram and the components defined therein in
order to achieve the required level of suppression

C1: Capacitor 1 µF
C2: Capacitor 1000 µF
L1: Choke coil 6 µH

Fig. 1: Electrical diagram of the supplemental circuit

5.3. Pneumatic connection

Connected

components

Pump exhaust

 Only connect components to the pump which are designed for

the pneumatic data of the pump (see Chapter4, Technical da­ta).

 If the pump is used as a vacuum pump, safely discharge the

pump exhaust.

Connecting pump

A marking on the pump head shows the direction of flow.

1. Remove the protective plugs from the hose connectors.

2. The accessory silencer/filter (where applicable) is put onto the
hose connector.

3. Connect the suction line and pressure line (tube ID 4 mm).

4. Lay the suction and pressure line at a downward angle to
prevent condensate from running into the pump.

8 Translation of original Operating and Installation Instructions, english, KNF 121571-121574 06/14

Swing Piston Pumps NPK 04 Operation

sure line is throttled or regulated, make sure that

on. This also applies in operation following a brief power

6. Operation

Only operate the pumps under the operating parameters and
conditions described in Chapter 4, Technical data.

Make sure the pumps are used properly (see section 2.1).

Make sure the pumps are not used improperly (see section 2.2).

Observe the safety precautions (see Chapter 3).

Hazard of the pump head bursting due to excessive
pressure increase

 Do not exceed max. permissible operating

WARNING

pressure (see Chapter 4, Technical data).

 Only throttle or regulate the air quantity (the gas

quantity) in the suction line to prevent the maxi­mum permissible operating pressure from being
exceeded.

 If the air quantity (the gas quantity) in the pres-

Pump standstill

Silencer/filter

Switching pump on

the maximum permissible operating pressure is
not exceeded.

 Watch pressure during operation.

 If the pressure reaches the maximum permissi-

ble operating pressure of the pump, shut down
pump and eliminate faults (see section 7).

Excessive pressure (with all of the related hazards) can be
prevented by placing a bypass line with a pressure-relief valve
between the pressure and suctions sides of the pump. For
further information, contact our technical adviser (see front
page for telephone number).

 With the pump at a standstill, open pressure and suction lines

to normal atmospheric pressure.

Change the silencer/filter (accessory) if it is dirty.

The pump may not start up against pressure or vacuum during
switch­failure.

 Make sure that normal atmospheric pressure is present in the

lines during switch-on.

Translation of original Operating and Installation Instructions, english, KNF 121571-121574 06/14 9

Troubleshooting Swing Piston Pumps NPK 04

Disconnect the pump power supply before working

7. Troubleshooting

Extreme danger from electrical shock!



on the pump.

DANGER

Check the pump (see Tab. 8 and 9).

Pump does not transfer

Cause Fault remedy
Connections or lines blocked.  Check connections and lines.

 Remove blockage.

External valve is closed or filter
is clogged.

Condensate has collected in
pump head.

Piston seal or valve plates are
worn.

Flow rate, pressure or vacuum too low

 Check external valves and filters.

 Install pump at highest point in system.

 Replace pump.

Tab. 8

 Make sure the pump is deenergized and secure.

The pump does not achieve the output specified in the Technical data or the data sheet.
Cause Fault remedy
Condensate has collected in

pump head.
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.

Leaks occur on connections,
lines or pump head.

Connections or lines completely
or partially jammed.

Head parts are soiled.  Clean head components.

Piston seal or valve plates are
worn.

 Install pump at highest point in system.

 Change the pressure conditions.

 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.

 Eliminate leaks.

 Check connections and lines.
 Remove the jamming parts and particles.

 Replace pump.

Tab. 9

10 Translation of original Operating and Installation Instructions, english, KNF 121571-121574 06/14

Swing Piston Pumps NPK 04 Accessory

Fault cannot be rectified

If you are unable to determine any of the specified causes, send
the pump to KNF Customer Service (see last page for the ad­dress).

In order for KNF to repair the pump, the customer must provide a
statement on the media which were pumped and on pump clean­ing. Please fill out the corresponding KNF form, and submit it
together with the pump. A sample statement for copying can be
found in section 10 of these Operating and Installation Instructions.

8. Accessory

Accessories Order No.
Silencer/filter 024805

Tab. 10

Translation of original Operating and Installation Instructions, english, KNF 121571-121574 06/14 11

Returns Swing Piston Pumps NPK 04

9. Returns

Pumps and systems used in laboratories and process-based
industries are exposed to a wide variety of conditions. This means
that the components contacting pumped media could become
contaminated by toxic, radioactive, or otherwise hazardous sub­stances.

For this reason, customers who send any pumps or systems back
to KNF must submit a Health and safety clearance and decontami­nation form in order to avoid a hazardous situation for KNF em­ployees. This Health and safety clearance and decontamination
form provides the following information, among other things:

 physiological safety

 whether medium-contacting parts have been cleaned

 whether the equipment has been decontaminated

 media that have been pumped or used

and must declare physiological safety. To ensure worker safety,
work may not be started on pumps or systems without a signed
Health and safety clearance and decontamination form.

For optimal processing of a return, a copy of this declaration
should be sent in advance via e-mail, regular mail, or fax to KNF
Customer Service (refer to final page for address). In order to avoid
endangering employees who open the shipment's packaging,
despite any residual hazards, the original version of the Health and
safety clearance and decontamination form must accompany the
delivery receipt on the outside of the packing.

The template for the Health and safety clearance and decontami­nation form is included with these operating instructions and may
also be downloaded from the KNF website.

The customer must specify the device type(s) and serial number(s)
in the Health and safety clearance and decontamination form in
order to provide for the unambiguous assignment of the Declara­tion to the device that is sent to KNF.

In addition to the customer's declaration of physiological safety,
information about operating conditions and the customer's applica­tion are also of importance to ensure that the return shipment is
handled appropriately. Therefore, the Health and safety clearance
and decontamination form requests this information as well.

12 Translation of original Operating and Installation Instructions, english, KNF 121571-121574 06/14

Swing Piston Pumps NPK 04 Health and safety clearance and decontamination form

10. Health and safety clearance and decon­tamination form

Translation of original Operating and Installation Instructions, english, KNF 121571-121574 06/14 13

KNF worldwide

Benelux

Netherlands

KNF Verder B.V.

Utrechtseweg 4a
NL-3451 GG Vleuten
Tel. [phone]
Fax [phone]
E-mail: [e-mail]

www.knf-verder.nl

Benelux

Belgium, Luxembourg

KNF Verder N.V.

Kontichsesteenweg 17
B-2630 Aartselaar
Tel. [phone]
Fax [phone]
E-mail: [e-mail]

www.knf.be

China

KNF Neuberger Trading

(Shanghai) Co., Ltd
No. 36 Lane 1000
Zhang Heng Road
Shanghai 201203, P.R. China
Tel. [phone]
Fax [phone]
E-mail: [e-mail]

www.knf.com.cn

Germany

KNF Neuberger GmbH

Alter Weg 3 D-79112 Freiburg
Tel. [phone]
Fax [phone]
E-mail: [e-mail]

www.knf.de

France, Morocco,
Algeria

KNF Neuberger SAS

4, Bld. d’Alsace Z.I.
F-68128 Village-Neuf
Tel. [phone]
Fax [phone]
E-mail: [e-mail]

www.knf.fr

Great Britain

KNF Neuberger U.K. Ltd.

Avenue 2
Station Lane
Industrial Estate
Witney Oxon OX28 4FA
Tel. [phone]
Fax [phone]
E-mail: [e-mail]

www.knf.co.uk

India

KNF Pumps + Systems
(India) Pvt. Ltd.

RAJIV GANDHI INFOTECH PARK
Phase 1
Ganga Estate, Survey No. 152/2/2
Above AXIS BANK
Hinjewadi
Pune 411 057
Tel. [phone]
0091 (0)20 640 08 923
Fax [phone]
E-mail: [e-mail]

www.knfpumps.in

Italy

KNF ITALIA S.r.l.

Via Flumendosa, 10
I-20132 Milano
Tel. [phone]
Fax [phone]
E-mail: [e-mail]

www.knf.it

Japan

KNF Japan Co.Ltd.

Across Shinkawa Bldg. Annex 3F
1-16-14 Shinkawa, Chuo-ku,
Tokyo, Japan 104-0033
Tel. [phone]
Fax [phone]
E-mail: [e-mail]

www.knf.co.jp

Korea

KNF Neuberger Ltd.

Woosan Bldg.RM#202,
336-4, Hwikyung-Dong
Dongdaemun-Ku.,
130-090, Seoul
Tel. [phone]
Fax [phone]
E-mail: [e-mail]

www.knfkorea.com

Sweden, Denmark,
Finland, Norway

KNF Neuberger AB

Mejerivägen 4,
P.O. Box 44060
SE-10073 Stockholm
Tel. [phone]
Fax [phone]
E-mail: [e-mail]

www.knf.se

Switzerland

Sales

KNF Neuberger AG

Stockenstrasse 6
CH-8362 Balterswil
Tel. [phone]
Fax [phone]
E-mail: [e-mail]

www.knf.ch

Taiwan

KNF Neuberger Ltd.

9-2 FL., No., 24, Lane 123,
Section 6,
Ming Chuan East Road
Taipei City, Taiwan
Tel. [phone]
Fax [phone]
E-mail: [e-mail]

www.knftwn.com.tw

USA, Canada, South America

KNF Neuberger, Inc.

Two Black Forest Road
Trenton, New Jersey
08691-1810
Tel. [phone]
Fax [phone]
E-mail: [e-mail]

www.knfusa.com

South America
Direct Phone: [phone]
E-mail: [e-mail]

KNF product centres

Product centre for gas
pumps:

Germany

KNF Neuberger GmbH

Alter Weg 3
D-79112 Freiburg
Phone [phone]
Fax [phone]
E-mail: [e-mail]

www.knf.de

Product centre for fluid
pumps:

Switzerland

KNF FLODOS AG

Wassermatte 2
CH-6210 Sursee
Phone [phone]
Fax [phone]
E-mail: [e-mail]

www.knf-flodos.ch

Product centre for micro
pumps:

Switzerland

KNF Micro AG

Zelglimatte 1b
CH-6260 Reiden
Tel. [phone]
Fax [phone]
E-mail: [e-mail]

www.knf-micro.ch