KNF NPK 03 KV DC-M User manual

KNF Micro BA314221-314224 NPK03-EN-1217
Translation of original Operating and Installation Instructions, English Keep for future use
Operating and Installation Instructions
Swing Piston Compressors
Type range:
NPK 03 KV DC-M
NPK 03 KV DC-B4
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 “PJM“ or “PMM“) there could be differences in detail. For customer-specified projects please there-
fore take into account any agreed technical specifications, as well as these instructions.
Contents Page
1. About this document................................................................. 2
2. Use ........................................................................................... 3
3. Safety ....................................................................................... 4
4. Technical data .......................................................................... 6
5. Assembly and function ............................................................. 8
6. Operation................................................................................ 10
7. Servicing................................................................................. 12
8. Troubleshooting...................................................................... 13
9. Decontamination declaration..............Fehler! Textmarke nicht
definiert.
Product centre for
micro pumps
KNF Micro AG
Zelglimatte 1b
CH-6260 Reiden
Switzerland
Tel. [phone]
Fax [phone]
www.knf.com

Swing Piston Compressor NPK03 About this document
KNF Micro BA314221-314224 NPK03-EN-1217
Translation of original Operating and Installation Instructions, English 2
1. About this document
1.1. Use of the Operating and Installation Instruc-
tions
The Operating and Installation Instructions are part of the pump.
Forward the Operating and Installation Instructions to any sub-
sequent owners of the pump
Customer-specific project pumps (pump models which begin with
"PJM" or "PMM") may differ from the Operating and Installation In-
structions.
In the case of project pumps, take note of any additionally
agreed specifications.
1.2. Symbols and markings
Warning
WARNING
This symbol indicates a potential danger.
It also indicates the possible consequences of fail-
ure to observe the warning. The signal word (e.g.
"Warning") indicates the level of danger
Here you will see actions for avoiding the dan-
ger and potential consequences.
Danger levels
Signal word
Meaning
Consequences if not observed
DANGER
warns of immedi-
ate danger
Consequences are death or se-
rious injury and/or serious prop-
erty damage.
WARNING
warns of poten-
tial danger
Death or serious injury and/or
serious damage to property are
possible
CAUTION
warns of a poten-
tially dangerous
situation
Minor injury or damage to prop-
erty are possible.
Tab. 1
Other information and symbols
This indicates a required activity (step).
1. This indicates the first step of a required activity. Additional
consecutively numbered steps follow
This symbol indicates important information
Project pumps

Swing Piston Compressor NPK03 Use
KNF Micro BA314221-314224 NPK03-EN-1217
Translation of original Operating and Installation Instructions, English 3
2. Use
2.1. Intended use
KNF pumps are to transfer, evacuate and compress gases.
Owner's responsibility
Only install and operate the pumps under the operating parameters
and conditions described in Chapter 4, Technical data. Only com-
pletely installed pumps may be taken into service.
Before using a medium, check whether the medium can be trans-
ferred danger-free in the specific application case.
Before using a medium, check the compatibility of the materials of
the pump head, pump housing, piston seal, piston screw and
valves with the medium.
The temperature of the medium must lie within the permissible
temperature range (see Chapter 4).
The transferred gas should not contain particles as these can pre-
vent the pump from working correctly. If this cannot be guaranteed,
a filter < 50 m with sufficiently large filter area must be used up-
stream of the pump.
See the type- plate or data sheet for full electrical and pneumatic
data.
2.2. Improper use
DANGER
The pumps must not be operated in an explo-
sive atmosphere.
The pumps are not suitable for transferring dusts and liquids.
Please contact your local KNF partner for special designs that
are not included in the technical specification.
Operating parameters and
conditions
Requirements for
transferred medium

Swing Piston Compressor NPK03 Safety
KNF Micro BA314221-314224 NPK03-EN-1217
Translation of original Operating and Installation Instructions, English 4
3. Safety
Observe the safety precautions in Chapters
5. Installation and connection and 6. Operation.
The pumps are built according to the generally recognized rules of
technology and in accordance with the pertinent occupational
safety and accident prevention regulations. Nevertheless, dangers
may occur during their use which may lead to injuries to the user or
others, or to damage to the pump or other property.
Only use the pumps when they are in a good technical and proper
working order, in accordance with their intended use, observing the
safety advice within the Operating and Installation Instructions, at
all times.
Make sure that only trained and instructed personnel or specially
trained personnel work on the pumps. This especially applies to
assembly, connection and servicing work.
Make sure that all personnel have read and understood the Oper-
ating and Installation Instructions, and in particular the "Safety"
chapter.
Always ensure adherence to all pertinent accident prevention and
safety regulations when working on and operating the pump.
When transferring dangerous media, observe the safety regula-
tions for handling such media.
Always ensure adherence to all information stickers on the pumps,
such as flow direction arrows and type plates, and keep stickers in
legible condition.
All replacement parts should be properly stored and disposed of in
accordance with the applicable environmental protection regula-
tions. Observe the respective national and international regula-
tions. This especially applies to parts contaminated with toxic sub-
stances.
Dispose of all packaging in an environmentally-appropriate
manner. The packaging materials are recyclable.
Dispose of end-of-life equipment in an environmentally
friendly manner. Use appropriate waste collection systems
for the disposal of end-of-life equipment. Used pumps con-
tain valuable recyclable materials.
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 machinery is to be assembled
conforms to 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.
General Principles No. 1
No. 1.1.2. / 1.1.3. / 1.3.1. / 1.3.3. / 1.3.4. / 1.4.1. 1.5.1 /1.5.2 / 1.5.8.
/ 1.5.9./ 1.7.4. / 1.7.4.1. / 1.7.4.3.
Personnel
Working in a
safety-conscious manner
Handling dangerous media
Notes
Environmental protection
Disposal
EU directives/standards

Swing Piston Compressor NPK03 Safety
KNF Micro BA314221-314224 NPK03-EN-1217
Translation of original Operating and Installation Instructions, English 5
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, hot
parts, if existing, has to be provided when mounting.
The pumps comply with the fundamental requirements of Directive
2011/65/EU (RoHS2).
All repairs to the pump(s) must be carried out by the relevant KNF
customer service team.
Exception service interval: see 7.3.
Customer service and repairs

Swing Piston Compressor NPK03 Technical data
KNF Micro BA314221-314224 NPK03-EN-1217
Translation of original Operating and Installation Instructions, English 6
4. Technical data
General parameters
Parameter
Value
Allowed ambient temperature (°C)
+5°C to + 40°C
Allowed medium temperature (°C)
+5°C to + 40°C
Allowed storage temperature (°C)
- 20°C to + 70°C
Tab. 3
Pump Materials of gas-contacting parts
Type designation NPK 03 KV ..
Components
Material1)
Head plate, intermediate plate
PPS
Valve plate
FPM
O-ring
FPM
Sealing lid
PTFE
Clamping disc
Aluminium
Clamping disc screw
A4 (stainless steel)
Tab. 4
DC stands for NPK 03 KV DC-M
Motor specification
Supply voltage[V] 5)
12
24
Max power consumption [W]
18
18
Connection[-]
Wires AWG20
Protection class [-]
IP 40
Weight 1) [g]
480
Delivery rate [l/min] 2), 3)
3
Max. operating pressure [bar g] 2), 3)
5.5
Max. vacuum [mbar abs] 2), 3)
250
Tab.5
DCB stands for NPK 03 KVDC-B4 (brushless)
B4: Brushless motor with internal electronic and controllability
Motor Variants
Supply voltage[V] 5)
12
24
Max. power consumtion [mW]
14
14
Connection [-]
Wires AWG24
Protection class [-]
IP 20
Weight 1) [g]
380
Delivery rate [l/min] 2), 3)
2.7
Max. operating pressure [bar g] 2), 3)
5.5
Max. vacuum [mbar abs] 2), 3)
250
Tab.6
1) The weight may differ slightly from the stated value, depending on the version.
2) Depending on the application level (MASL), ambient temperature, material design
of the pump head and the connection hoses used, the flow rates may vary from the
values shown.
3) Measured with air at 20°C / at atmospheric pressure
5) Nominal use

Swing Piston Compressor NPK03 Technical data
KNF Micro BA314221-314224 NPK03-EN-1217
Translation of original Operating and Installation Instructions, English 7
Motor electrical specifications DC-B4 12V / 24V
Electrical connections
Function
Lead color
Signal name
Size
+ Supply voltage
Red
+ Vs
AWG 24
- Supply voltage
Blue
- Vs / GND
AWG 24
Speed control –input
signal
White
Vctrl
AWG 24
Frequency output –
output signal
Green
FG
AWG 24
DC control input Vctrl
Control voltage range DC
0...5
[VDC]
Speed range
950 .. 2850
[1/min]
Resistant to surge voltages up to
30
[VDC]
Threshold voltage
1.0
(VDC)
Speed/voltage constants
950
(rpm/V)
FG frequency output
FG pulses per mech. revolution
6
[ ]
Output level "high" (Iout <0.1mA)
4.2 … 5.4
[V]
Output level "low" (Iout <0.1mA)
< 0.5
[V]
Tab.7

Swing Piston Compressor NPK03 Assembly and function
KNF Micro BA314221-314224 NPK03-EN-1217
Translation of original Operating and Installation Instructions, English 8
5. Assembly and function
Only install the pump under the operating parameters and condi-
tions 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 ambient
Make sure that the installation location is dry and the pump is
protected against water in the form of rain, spray, splashes and
drips.
Protect the pump against dust.
Protect the pump against vibration and impact.
WARNING
Risk of physical injury and damage to the pump due
to automatic start
If the pump overheats and the thermal switch /
electronics stops pump operation, the pumps will
restart automatically as soon as the motor has
had time to cool down.
Take steps to ensure that this cannot produce a haz-
ardous situation
5.2. Electrical connection
Only have the pump connected by an authorized specialist
Only have the pump connected when the power supply is dis-
connected.
When connecting the device to a power source, the relevant
norms, directives, regulations and technical standards must be
observed
Connecting the pump
1. Make sure that the power supply data match the data on the
motor's type plate. The current consumption can be found on
the type plate.
2. Connect the motor cables. For electrical data see Chapter 4.
Note the proper polarity.
For DC motors:
red motor cable: +
black motor cable: -
In the case of brushless DC motors:
incorrect polarity may damage to the electronics.
Installation location
Contact and foreign body pro-
tection

Swing Piston Compressor NPK03 Assembly and function
KNF Micro BA314221-314224 NPK03-EN-1217
Translation of original Operating and Installation Instructions, English 9
5.3. Pneumatic connection
Only connect components to the pump that are designed to
handle the pneumatic data of the pump (see Chapter 4, Tech-
nical data)
Only use hoses that are suitable for the maximum operating
pressure of the pump (see Chapter 4)
Only use hoses that are chemically resistant to the media be-
ing pumped
5.3.1. Connecting the pump
Arrows on the pump head indicate the flow direction.
1. Remove the protective caps from the hose connections.
2. Connect the suction and pressure lines.
3. If the pump is used to build up pressure, make sure that all
transition joints between hose and pump are secure in order to
ensure that the hoses cannot come off.
4. Check that the hoses and transition joints (hose connect-
or/hose) are fitted correctly and securely.
5. Check that the system is leak-tight.
Connected
components
Hoses

Swing Piston Compressor NPK03 Operation
KNF Micro BA314221-314224 NPK03-EN-1217
Translation of original Operating and Installation Instructions, English 10
6. Operation
Operate the pumps only under the operating parameters and
conditions described in Chapter 4, Technical data
Make sure that the pumps are being used properly (see Chap-
ter 2.1).
Avoid improper use of the pumps (see Chapter 2.2)
Observe the safety precautions (see Chapter 3).
The pump is a component intended to be incorporated into an-
other machine. Before putting into service it must be estab-
lished that the machinery or systems in which the pump is in-
stalled meets the relevant regulations
CAUTION
Risk of burning
The drive heats up.
Avoid contact with the pump drive.
Avoid contact with flammable materials
Excessive pressure and the inherent dangers thereof can be
prevented by placing a bypass line with a pressure relief valve
between the pressure and suction side of the pump. Please
contact your local KNF partner for further information
(www.knf.com).
If the pump stops running, restore the system to normal atmos-
pheric pressure.
For pumps with thermal switch or electronic overload protection:
WARNING
Risk of physical injury and damage to the pump
due to automatic start
If the pump overheats and pump operation is
stopped by the thermal switch / electronics, the
pumps will restart automatically as soon as the motor
has had time to cool down
Take steps to ensure that this cannot produce a
hazardous situation
Regularly inspect the pump for external damage or leaks.
Pump standstill
Inspection

Swing Piston Compressor NPK03 Operation
KNF Micro BA314221-314224 NPK03-EN-1217
Translation of original Operating and Installation Instructions, English 11
Switching the pumps on
In order to guarantee that the pump can start every time it is
advisable to reduce the back pressure to an acceptable level.
This is also the case if there is a short power cut.
For more specific information contact the KNF specialist
Switching the pumps off
Ensure that the system is subject to normal atmospheric pres-
sure (release the hydraulic pressure.
The motor speed of the pump, and thus the flow rate, is adjust-
able and can also be regulated to some extent.
For more details, see Chapter 4, Technical data
Duty cycle / impulse operation
For pressures above 2bar g the switch-on duration has to be lim-
ited.
Above 2bar g, we recommend a max. switch-on duration of 5 min.
The switch-on/off time depends on the heat in the pump head and
its heat dissipation / cooling down while switched off.
During operation, a maximum temperature of 105°C should not be
exceeded in the pump head. The temperature has to be measured
on the pressure side of the pump head.
For more specific information contact the KNF specialist
Contact information: www.knf.com
Short start and stop cycles may adversely affect the service life of
the brushed motors
If the pump is operated with short cycles in your application,
please contact a KNF pump specialist for further information
(Telephone number: www.knf.com)
Setting and regulating motor
speed
Duty cycle
Impulse operation

Swing Piston Compressor NPK03 Servicing
KNF Micro BA314221-314224 NPK03-EN-1217
Translation of original Operating and Installation Instructions, English 12
7. Servicing
7.1. Servicing schedule
Component
Servicing interval
Pump
-Regular inspection for external
damage or leaks
Tab. 9
7.2. Cleaning
7.2.1. Cleaning the pump
The pump, if necessary clean outside with a dry wipe. Do not
use cleaning solvents as these may corrode plastic parts.
Isolate the pump from the power supply.
Pump must be free of any hazardous substances
Hoses must be disconnected from the pump
7.3. Service Intervall
7.3.1. Version with DC –Motor
For DC-motors no Service Interval is necessary
7.3.2. Version with DC –B Motor
The recommended service interval for brushless motors is
5000hr.
For Service: Spare part kit 314101 is available
Contained parts:
Sealing lid 1pcs.
O-Ring 2pcs.
Valve plate 2pcs.
Clamping disc screw 1pcs.
Operational manual see is enclosed at spare part kit.
Please note, spacers below clamping disc and con rod have to
be secured. Same spacers have to be reused.
Otherwise function is not guaranteed
Prior requirements

Swing Piston Compressor NPK03 Troubleshooting
KNF Micro BA314221-314224 NPK03-EN-1217
Translation of original Operating and Installation Instructions, English 13
8. Troubleshooting
Pump does not work
Cause
Fault remedy
Pump not connected to power
supply
Connect pump to power supply
Power supply is not switched on
Switch on power supply
Thermal switch or pump elec-
tronics have responded
Disconnect pump from mains power supply.
Allow pump to cool.
Identify and eliminate cause of overheating/overload
Connections or pipes are
blocked.
Check pipes and connections.
Remove blockage.
External valve is closed or filter
is blocked
Check external valves and filters.
Sealing lid, valves or gaskets
are worn out
Service according 7.3
Contact customer service
Tab. 10
Flow rate, pressure or vacuum too low
The pump does not achieve the output specified in the Technical data or the data sheet
Cause.
Fault remedy
Components in the system
connected to the suction and
pressure sides, such as hoses,
valves or filters, are causing too
much resistance
Modify installation, check the cross-sections of components
Hose connections are not leak
tight
Secure transition joints between hose and hose connections
with clamps or clamping elements
Particles in the pump
Clean the pump head, install suction-side filter if required
Incorrect interchange of pres-
sure and suction line connec-
tions
Remove pressure and suction lines and reconnect correctly
The pump parts are not re-
sistant to the medium to be
transferred
Replace the pump head with a compatible version
Sealing lid, valves or gaskets
are worn out
Service according 7.3
Contact customer service
Tab. 11
Fault cannot be rectified
If you are unable to identify any of the above causes, please send
the pump to KNF customer service (see address on last page).
1. Isolate the pump from the power supply and remove the pump
from the system.
2. Clean the pump (see Chapter 7.2.1)
3. Send the pump, with completed decontamination declaration
(see Chapter 9), to KNF customer service stating the nature of
the transferred medium.

Swing Piston Compressor NPK03 Returns
KNF Micro BA314221-314224 NPK03-EN-1217
Translation of original Operating and Installation Instructions, English 14
9. Returns
9.1. General
Pumps and systems used in laboratories and process-based in-
dustries are exposed to a wide variety of conditions. This means
that the components contacting pumped media could become con-
taminated by toxic, radioactive, or otherwise hazardous sub-
stances.
For this reason, customers who send any pumps or systems back
to KNF must submit a Health and safety clearance and decontami-
nation form in order to avoid a hazardous situation for KNF em-
ployees. 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.
The template for the Health and safety clearance and decontami-
nation form is included with these operating instructions and may
also be downloaded from the KNF website www.knf.com/down-
loads.
The customer must specify the device type(s) and serial number(s)
in the Health and safety clearance and decontamination form in or-
der 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, in-
formation about operating conditions and the customer's applica-
tion 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.
9.2. For North American Customers
To ensure the safety of our customers and our associates, KNF
Neuberger, Inc. requires that all products returned to their facility
include a Return Material Authorization (RMA) number. For com-
plete information on KNF Neuberger Inc. pump repairs, service and
maintenance please visit www.knfusa.com/ProductReturns

Swing Piston Compressor NPK03 Health and safety clearance and decontamination form
KNF Micro BA314221-314224 NPK03-EN-1217
Translation of original Operating and Installation Instructions, English 15
10. Health and safety clearance and decon-
tamination form

Swing Piston Compressor NPK03
KNF Micro BA314221-314224 NPK03-EN-1217
Translation of original Operating and Installation Instructions, English 16
KNF worldwide
Find our local KNF partner on: www.knf.com

Swing Piston Compressor NPK03
KNF Micro BA314221-314224 NPK03-EN-1217
Translation of original Operating and Installation Instructions, English 17