Instruction Manual
Diaphragm Pump series N
Version N3 KPE, N3 KP18
N5 KPE, N5 KP18
N9 KPE, N9 KP18
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List of Contents
1 General information ............................................................................................................... 4
2 Declaration of conformity ...................................................................................................... 4
3 Safety instructions ................................................................................................................. 5
4 Warranty .................................................................................................................................. 5
5 Used terms and signal indications ....................................................................................... 6
6 Introduction ............................................................................................................................. 7
7 Application .............................................................................................................................. 7
7.1 Ambient conditions ................................................................................................................ 7
7.2 Safety instructions ................................................................................................................. 8
8 Technical data ......................................................................................................................... 9
9 Receipt of goods and storage ............................................................................................... 9
10 Installation instructions ......................................................................................................... 9
10.1 Mechanical installation ........................................................................................................ 10
10.2 Electrical installation ............................................................................................................ 12
10.3 Pneumatic............................................................................................................................ 13
11 Supply line connections ...................................................................................................... 13
11.1 Hose-/Tube connections ..................................................................................................... 13
12 Starting .................................................................................................................................. 14
13 Closing down ........................................................................................................................ 14
14 Maintenance .......................................................................................................................... 14
14.1 Removing the pump head type N 3/5/9 KPE/KP18 ............................................................. 15
14.2 Changing the diaphragm type N 3/5/9 KPE/KP18 ............................................................... 16
14.3 Changing the valve plates type N 3/5/9 KPE/KP18 ............................................................. 16
14.4 Refitting the pump heads type N 3/5/9 KPE/KP18 .............................................................. 16
14.5 Cleaning .............................................................................................................................. 16
15 Trouble shooting .................................................................................................................. 18
16 Spare parts list ...................................................................................................................... 19
17 Appendix ............................................................................................................................... 20
List of Figures
Figure 1 Dimensions (mm) N3/5 KPE........................................................................................... 10
Figure 2 Dimensions (mm) N9 KPE.............................................................................................. 10
Figure 3 Dimensions (mm) N3/5 KP18 .......................................................................................... 11
Figure 4 Dimensions (mm) N9 KP18 ............................................................................................. 11
Figure 5 Electrical connections ...................................................................................................... 12
Figure 6 Sectional drawing N3/5 KPE ........................................................................................... 15
Figure 7 Sectional drawing N9 PE ................................................................................................. 15
Figure 8 Pump capacity N3/5 KPE/KP18 ...................................................................................... 21
Figure 10 Pump capacity N9 KPE/KP18 .......................................................................................... 21
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This Operating Manual does not claim completeness and may be
subject to technical modifications.
© 06/2002 M&C TechGroup Germany GmbH. Reproduction of this
document or its content is not allowed without permission from M&C.
6th edition: 03/2011
Dear customer,
we have made up this operating manual in such a way that all necessary information about the product can be found and understood quickly and easily.
Should you still have any question, please do not hesitate to contact M&C directly or go through your
appointed dealer. Respective contact addresses are to be found in the annexe to this operating manual.
Please also contact our homepage www.mc-techgroup.com for further information about our products. There, you can read or download the data sheets and operating manuals of all M&C products as
well as further information in German, English and French.
Gas sampling and conditioning technology 6-1.2.1ME
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Head Office
M&C TechGroup Germany GmbH Rehhecke 79 40885 Ratingen Germany
Telephone: 02102 / 935 - 0
Fax: 02102 / 935 - 111
E - mail: info@mc-techgroup.com
www.mc-techgroup.com
1 GENERAL INFORMATION
The product described in this operating manual has been examined before delivery and left our works
in perfect condition related to safety regulations. In order to keep this condition and to guarantee a
safe operation, it is important to heed the notes and prescriptions made in this operating manual.
Furthermore, attention must be paid to appropriate transportation, correct storage, as well as professional installation and maintenance work.
All necessary information a skilled staff will need for appropriate use of this product are given in this
operating manual.
2 DECLARATION OF CONFORMITY
CE - Certification
The product described in this operating manual complies with the following EC directives:
EMV-Instruction
The requirements of the EC directive 2004/108/EC “Electromagnetic compatibility“ are met.
Low Voltage Directive
The requirement of the EC directive 2006/95/EC “Low Voltage Directive“ are met.
The compliance with this EC directive has been examined according to DIN EN 61010.
Declaration of conformity
The EU Declaration of conformity can be downloaded from the M&C homepage or directly requested
from M&C.
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3 SAFETY INSTRUCTIONS
Please take care of the following basic safety procedures when mounting, starting up or operating this equipment:
Read this operating manual before starting up and use of the equipment. The information and warnings given in this operating manual must be heeded.
Any work on electrical equipment is only to be carried out by trained specialists as per the regulations
currently in force.
Attention must be paid to the requirements of VDE 0100 (IEC 364) when setting high-power electrical
units with nominal voltages of up to 1000 V, together with the associated standards and stipulations.
Check the details on the type plate to ensure that the equipment is connected to the correct mains
voltage.
Protection against touching dangerously high electrical voltages:
Before opening the equipment, it must be switched off and hold no voltages. This also applies to any
external control circuits that are connected.
The device is only to be used within the permitted range of temperatures and pressures.
Check that the location is weather-protected. It should not be subject to either direct rain or moisture.
The pumps type N3/5/9.. must not be used in hazardous areas.
Installation, maintenance, monitoring and any repairs may only be done by authorized personnel with
respect to the relevant stipulations.
4 WARRANTY
If the equipment fails, please contact M&C directly or else go through your M&C authorised dealer.
We offer a one year warranty as of the day of delivery as per our normal terms and conditions of sale,
and assuming technically correct operation of the unit. Consumables are hereby excluded. The terms
of the warranty cover repair at the factory at no cost or the replacement at no cost of the equipment
free ex user location. Reshipments must be send in a sufficient and proper protective packaging.
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DANGER!
This means that death, severe physical injuries and/or important
material damages will occur in case the respective safety measures
are not fulfilled.
W AR NIN G!
This means that death, severe physical injuries and/or important
material damages may occur in case the respective safety measures are not fulfilled.
CARE!
This means that minor physical injuries may occur in case the
respective safety measures are not fulfilled.
CARE!
Without the warning triangle means that a material damage may
occur in case the respective safety measures are not met.
ATT ENT IO N!
This means that an unintentional situation or an unintentional status
may occur in case the respective note is not respected.
NOTE!
These are important information about the product or parts of the
operating manual which require user’s attention.
SKILLED STAFF
These are persons with necessary qualification who are familiar with
installation, use and maintenance of the product.
5 USED TERMS AND SIGNAL INDICATIONS
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Partnumber
Type
Material
Pump head
Diaphragm
Valve
Sealing
02P3351
N 3 KPE
PVDF
PTFE-beschichtet
Viton
Viton
02P3006
N 3 KP18
02P3355
N 5 KPE
02P3007
N 5 KP18
02P3360
N 9 KPE
02P3008
N 9 KP18
NOTE!
The diaphragm pumps series N 3/5/9 are not applicable for sampling liquids.
Before use please check the compatibility of the material (see table
1).
WA RNI NG !
The pumps series N 3/5/9 are not allowed to be used in hazardous
areas.
6 INTRODUCTION
The compact diaphragm pumps type N3/5/9 are suitable for sampling air, gases and vapours in a
temperature range between + 5 °C and + 40 °C. The construction and the pump capacity are adapted
to the requirements of the gas analysis technique.
7 APPLICATION
The sampling evacuation and compression of the diaphragm sample pump series N3/5/9 is 100% oilfree. The operation is gas-tight and maintenance-free.
The noise level of the pump without housing is less than 55 dB(A).(pneumatically connected).
Material abbreviations according to ISO 1629 and 1043.1
Table 1 Pump materials
7.1 AMBIENT CONDITIONS
When the pump is operating the following ambient conditions must be maintained:
Ambient temperature during operating: + 5°C .... + 40°C.
The pump must be protected from the effects of dust and water.
During operating an adequate supply of air for cooling must be provided.
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WA RNI NG !
Protection against the contact with electrical and moving parts
respectively the penetration of particles into the pump has to be
provided externally.
NOTE!
Do not use pumps series N 3/5/9 in hazardous areas.
The pumps may only be used for their intended purpose.
Components connected to the pump must be designed according
to the pneumatic performance of the pump. (see technical data)
Take care that safety regulations are observed when connecting
the pump to the power supply.
Specific safety instructions concerning sample must be observed.
WA RNI NG !
Aggressive sample is possible.
Wear protective glasses and proper protective clothing during
disassambly, repair or cleaning!
7.2 SAFETY INSTRUCTIONS
The protection class of the pumps series N3/5/9 KPE is IP00.
The protection class of the pumps series KP18 is IP20.
Both pump types have no protection against water. Please provide protection before start-up.
The thermo-switch shuts off the pump when the pump temperature exceeds the high temperature
level. After cooling down the pump restarts automatically.
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8 TECHNICAL DATA
Diaphragm Pump Series
N3 KPE / N3 KP18
N5 KPE / N5 KP18
N5 KPE / N5 KP18
Part Number
02P3351 / 02P3006
02P3355 / 02P3007
02P3360 / 02P3008
Max. operating pressure
0,25 bar – 3 bar abs.
0,15 – 3 bar abs.
0,15 – 1,5 bar abs.
Capacity at atm. pressure
3 Nl/min
5 Nl/min
9 Nl/min
Ambient temperature
+5°C...+40°C
Sample temperature
+5°C...+40°C
Storage temperature
-15°C bis +60°C
Mains power supply
230V/50Hz; 115V/60Hz
Power consumption
60W
0,75A(230V)/1,5A(115V)
60W
0,65A(230V)/1,2A(115V)
Electrical connection
KPE: Single wire 4x0,5mm²
KP18: wired by luster terminal
Electrical protection
N3/5KPE: must be fuse-protected with 1 fuse: 230V-3,7AT / 115V-
7,5AT
N9KPE: must be fuse-protected with 1 fuse: 230V-3,15AT / 115V-
6AT
KP18: is fuse-protected with 2 fuses: 230V / 115V-3,15AT
Preventing device
Thermal switch, double (115V/230V)
Connections
G 1/8“ i DIN ISO 228/1
Protection
KPE: IP00 KP18: IP20
Housing material KP18
Al-Mg-Si-0,5 / firmness: F25
Material of sample contacting parts
PVDF, Viton, PTFE
Weight
KPE : 1,1 kg
KP18 : 1,9 kg
KPE : 1,3 kg
KP18 : 2,1 kg
NOTE!
The equipment should be stored in a protected, frost-free room!
9
9 RECEIPT OF GOODS AND STORAGE
Please take the sample pump and possible special accessories carefully out of the packaging
immediately after receipt, and compare the goods with the items listed on the delivery note!
Check the goods for any damage caused during delivery and, if necessary, inform your transport
insurance company without delay of any damage discovered
10 INSTALLATION INSTRUCTIONS
All accident prevention regulations and safety instructions must be observed during installation and
operation. Please follow the instructions in chapter 3.
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NOTE!
Pumps have mechanical moving parts that can induce vibrations.
To prevent damages at the pump or at peripheral components /
facilities as well as minimizing noise development an appropriate
vibration decoupling is necessary. For this M&C can deliver e.g.
anti-vibration pads.
This explicit is also valid for the connection of the sample lines at
the pump head.
43
900
8
68
40
113
G1/8“
18
7,24864
4xM4
4xM4
Drehrichtung
52
900
8
G1/8“
22
74
40
119
48
57
64
95
31,5
10.1 MECHANICAL INSTALLATION
Figure 1 and figure 2 show the dimensions of the pumps.
When mounting the pump provide sufficient air ventilation.
Avoid acidents caused by the fan.
Install the pump at the highest place in the system and/or with the pump head showing down. This
avoids that condensate can be assembled inside the pump head.
Figure 1 Dimensions (mm) N3/5 KPE
Figure 2 Dimensions (mm) N9 KPE
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106
164
ca. 57
5
20
120
90
G1/8“
51,5
29,5
187
ca. 57590
132
G1/8“
Figure 3 Dimensions (mm) N3/5 KP18
11
Figure 4 Dimensions (mm) N9 KP18
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WAR NIN G!
When connecting the equipment, please ensure that the supply
voltage is identical with the information provided on the model
type plate.
The supply voltage is only allowed to deviate max. +6 % - 10% from
the indication on the model type plate.
NOTE!
Attention must be paid to the requirements of IEC 364 (DIN VDE
0100) when setting high-power electrical units with nominal voltages of up to 1000 V, together with the associated standards and
stipulations.
The main circuit of the pump type KPE must be equipped with a
fuse corresponding to the nominal current (over current protection); (EN 60335-1)
The main circuit of the pump type KP18 is equipped with a fuse
corresponding to the nominal current (over current protection);
(EN 60335-1)
For electrical details see technical data.
Mains 230V
N
L
wt
b/wt
rd
bl
Connection
Mains 115V
N L wt
b/wt
rd
bl
Connection
Bridge
10.2 ELECTRICAL INSTALLATION
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..
The earth wire (ground) must be connected to the motor.
The pump must be installed so that contact with live parts (connections, possibly windings) is
impossible.
We recommend that a fuse is installed in the motor supply circuit; the operating current is given in
the technical data
Figure 5 Electrical connections
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NOTE!
The pump must only be used in the conditions specified in the technical
data.
The pump should be installed away from heat sources and freely ventilated
to prevent any accumulation of heat.
For outdoor installation, the pump must be installed in a housing protected
from frost in the winter and sufficiently ventilated in summer. Exposure to
direct sunlight must be avoided.
NOTE!
Do not confuse hose-/tube connections for sample gas inlet and outlet; the
connections are labelled accordingly !
Check for tightness of all sample lines after connection (see 11.2) !
NOTE!
The tightness of the connections can only be guaranteed if the end section
of the connection hose/tube is flat (use a hose-cutter) !
10.3 PNEUMATIC
Remove the protection plugs from the port threads (thread size G1/8“).
Accessories like hose connections are screwed into the port threads by sealing tape (using M&C
connectors sealing tape is not necessary).
Connect the suction and pressure lines.
Arrange the suction and pressure lines so that condensate cannot run into the pump.
11 SUPPLY LINE CONNECTIONS
11.1 HOSE-/TUBE CONNECTIONS
The gas inlet and outlet hoses/tubes are connected on the top of the pump. Standard G 1/8" threaded
joints are available for the connection of the gas sample lines.
The appropriate tube or hose threaded joint connections are available optionally from M&C.
When connecting the sample gas supply hoses or tubes to the corresponding threaded connections,
pay attention to the following points:
Loosen the sleeve nut of the clamping-ring threaded joint by turning to the left. Take care that the
nut is removed carefully from the body of the threaded joint to avoid losing the clamping ring which
is mounted loose in the nut.
Push the sleeve nut over the connection hose/tube.
Push the clamping ring onto the connection hose/tube with the thicker bulge pointing to nut.
Push the hose/tube onto the supporting nipple in the threaded joint.
Tighten the sleeve nut by hand.
The hose/tube is now mounted in such a way that it cannot slip and is resistant to pressure.
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NOTE!
The area in which the pump is situated when not in use must be
kept free of frost at all times!
WAR NIN G!
It is necessary to take the pump off the mains before any assembly, maintenance or repair work is carried out!
12 STARTING
Specific safety instructions for media being handled must be observed.
Before pumping a medium, the compatibility of materials of pump head, diaphragm and valves with
the medium must be checked (for pump materials: see table 1).
The following steps should be carried out before initial start-up:
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 must be so even when the pump restarts after the power has been cut off for a short period.
The maximum permissible operating pressure (see technical date) must not be exceeded, even
when the flow is restricted.
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 pressure 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.
Diaphragm and valve plates are the only parts subject to wear. Wear is usually indicated by a
drastic reduction in the pneumatic performance. When replacing parts proceed as described in
section 10.
Ambient conditions: see technical data.
13 CLOSING DOWN
If the pump is putting out of action for a short time no particular measures need to be taken.
14 MAINTENANCE
Before the maintenance work is carried out, it is necessary that the specific safety procedures pertaining to the system and operational process be observed!
Diaphragm and valve plates are the only wearing parts of the pump. They are simple to change. A
wear is indicated by a drop of the pump capacity.
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NOTE!
Always change valve plates, diaphragm and sealing rings at the same
time.
3
4 2 9
1
13
16
14
11
7
8
Figure 6 Sectional drawing N3/5 KPE
Figure 7 Sectional drawing N9 PE
Parts and tools required:
Valve plates, sealing rings (2 for each pump head) and structured diaphragm(s)
Screwdriver no. 1
Change the diaphragm, valve plates and sealing rings in the following sequence:
Remove pump head
Change diaphragm
Change valve plates and sealing rings
Refit pump head
Proceed as follows:
14.1 REMOVING THE PUMP HEAD TYPE N 3/5/9 KPE/KP18
Make a mark on the head plate 3 (N3/5 with metal frame), intermediate plate 2 and housing 1
with a felt-tip pen. This helps avoid incorrect assembly later
Undo the screws 4 in the head plate with the intermediate plate off the pump housing.
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NOTE!
Valve plate and sealing ring for pump type N9 are connected to one
spare part since 02/2007.
14.2 CHANGING THE DIAPHRAGM TYPE N 3/5/9 KPE/KP18
Turn the fan to bring the structured diaphragm 9 to top dead centre.
Lift the edge of the diaphragm and gripping it on opposite sides unscrew it by turning anti-
clock-wise. Please take care that the diaphragm spacers 11 on the threaded portion of the
diaphragm do not fall into the housing.
Take the diaphragm spacer 11 off the threaded portion of the diaphragm and retain them.
Check that all parts are free from dirt and clean them if necessary.
Put the diaphragm spacer on the thread of the new diaphragm.
Turn the fan until the connecting rod 13 is at top dead centre.
Screw the diaphragm complete with diaphragm spacer into the connecting rod (clockwise)
and tighten it by hand.
14.3 CHANGING THE VALVE PLATES TYPE N 3/5/9 KPE/KP18
Separate the head plate 3 (N3/5 with metal frame) from intermediate plate 2.
Remove the valve plates 7 and sealing rings 8 from the intermediate plate.
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.
Lay the new valve discs in the recesses in the intermediate plate. The valve plates for suc-
tion and pressure sides are identical as are upper and lower sides of the plates.
Check that the valve plates are not deformed by moving them gently.
Lay the sealing rings on the intermediate plate.
14.4 REFITTING THE PUMP HEADS TYPE N 3/5/9 KPE/KP18
Turn the fan to bring the diaphragm to top dead centre.
Place the intermediate plate 2, with valve plates 7 and sealing rings 8, and head plate 3 on
the housing, in the position indicated by the markings.
Check that the head plate is centred by moving it gently sideways.
Place the metal frame for N3/5
Gently tighten the screws 4 evenly and diagonally.
Turn the fan to check that the pump rotates freely.
Turn the fan again to bring the diaphragm to top dead centre.
Now tighten screws 4 firmly.
14.5 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.
Gas sampling and conditioning technology 6-1.2.1ME
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WA RNI NG !
Aggressive medium possible.
Wear protective glasses and proper protective clothing!
For recommended spare parts please see Section 16.
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Problem/indication
Possible cause
Action/Check
Pump produces no
flow
No main supply.
Check power supply. Check plug for correct fit.
Thermal switch has opened
due to over-heating.
Disconnect pump from mains and allow to cool.
Race cause of over-heating and eliminate it.
Connections or lines are
blocked.
Remove blockade.
An external valve is closed
or a filter is blocked.
Open valve or clean blocked/dirty filter.
Liquid (condensate) has
collected in the pump head.
Let the pump for a few minutes pumping air.
Flow, pressure or
vacuum too low
Diaphragm or valves are
worn out.
Change diaphragm or/and valves.
Compare the actual performance with the figures in
the technical data.
The pump is not designed for this condition.
There is pressure on the
pressure side and at the
same time vacuum or a
pressure above atmospheric
on the suction side.
The pump is not designed for this condition.
The cross-section of pneumatic lines or connected
components is too small, or
they are restricted.
To measure the performance, disconnect the
pump from the system (smaller diameter tubing
or a valve can significantly affect performance).
A leak at a connector, in a
line or in the pump head.
Insulate the leak, tighten the screws, clean or
exchange dirty parts.
NOTE!
If the pump does not operate properly and you cannot find any of the
above mentioned faults, send it back to M&C.
If you send the pump for repair please include information about the
medium it was handling.
In particular, if it was handling aggressive substances our engineers
must be informed.
If you have been handling dangerous or highly aggressive gases please
clean the pump before despatch.
15 TROUBLE SHOOTING
Before working on the pump isolate the power supply securely, then check that the lines are not live.
The following tips for fault-finding are best employed in the sequence shown.
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Diaphragm sample pump N3/5/9 KPE/KP18
(C) consumable parts, (R) recommended spare parts, (S) spare parts
recommended quantity
being in operation [years]
C/R/S
1 2 3
Diaphragm pump type N3 KPE/KP18; N5 KPE/KP18
90P2100
Square cap type D3, 1/8“i for N3/N5 KPE/KP18
Material: PVDF
S - -
1
90P2120
Diaphragm type S3, for N3/N5 KPE/KP18,
Material: Viton, PTFE coated
C 1 2
3
90P2111
Valve plate type V3, for N3/N5 KPE/KP18,
1 piece, Material: Viton (2 pc. required)
C 2 4
6
90P2105
Intermediate plate type Z3, for N3/N5 PE/KP18
Material: PVDF
S - -
1
Diaphragm pump type N9 KPE/KP18
90P2200
Square cap type D9, 1/8“i for N9 KPE/KP18,
Material: PVDF
S - -
1
90P2220
Diaphragm type S9, for N9 KPE/KP18,
Material: Viton, PTFE coated
C 1 2
3
90P2211
Valve plate with sealing ring, for N9 KPE/KP18,
1 piece, Material: Viton (2 pc. required)
C 2 4
6
90P2205
Intermediate plate type Z9, for N9 KPE/KP18,
Material: PVDF
S - -
1
PVDF Male connectors with G-thread (ISO 1010031)
05V1045
Male connector
DN 4/6-G1/8“ Material:PVDF
S - -
2
05V1050
Male connector
DN 6/8-G1/8“ Material:PVDF
S - -
2
05V6600
Ferrule DN 4/6 PVDF
S 2 2
4
05V6602
Ferrule DN 6/8 PVDF
S 2 2
4
05V6605
Union nut DN 4/6 PVDF
S 2 2
4
05V6607
Union nut DN 6/8 PVDF
S 2 2
4
16 SPARE PARTS LIST
Wear, tear and replacement part requirements depend on specific operating conditions.
The recommended quantities are based on experience and are not binding.
Gas sampling and conditioning technology 6-1.2.1ME
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17 APPENDIX
Pump capacity of the diaphragm pump type N3...9 KPE/KP18
For further product documentation, please see our internet catalogue:
www.mc-techgroup.com
Gas sampling and conditioning technology 6-1.2.1ME
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Figure 8 Pump capacity N3/5 KPE/KP18
Figure 9 Pump capacity N9 KPE/KP18
Gas sampling and conditioning technology 6-1.2.1ME
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