KNF FK 1100 User manual

FK 1100
INSTALLATION INSTRUCTIONS
DIAPHRAGM PUMP
Before operating the pump and the accessories, please read the Installation Instructions
and safety precautions.

Installation Instructions FK 1100 Contents
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Table of contents
Page
1General.......................................................................................4
1.1 Information about the instructions 4
1.2 Warnings 4
1.3 Disclaimer 5
1.4 Manufacturer’s address 5
1.5 Supporting documents 5
2Safety.........................................................................................6
2.1 Intended use 6
2.2 Reasonably foreseeable misuse 6
2.3 Responsibility of the user 6
2.4 Product-specific risks 6
2.5 Customer service and repairs 8
3Installation.................................................................................9
3.1 Installation location 9
3.2 Mechanical mounting 9
3.3 Connecting the fluid system 10
3.4 Electrical connection 10
4Initial start-up..........................................................................11
5Maintenance............................................................................13
5.1 Cleaning 13
5.2 Preparing for dismantling 14
5.3 Dismantling the motor 14
5.4 Mounting the motor 14
5.5 Dismantling the pump head 15
5.6 Assembling the pump head 16
5.7 Mounting the motor 17
6Overpressure protection .27..................................................18
6.1 Dismantling and cleaning 18
6.2 Assembling 18
7Rectifying transfer problems.................................................20
8Spare parts..............................................................................21
9Returning the pump................................................................21

General Installation Instructions FK 1100
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1 General
1.1 Information about the instructions
The Installation Instructions describe the requirements for installing
the product correctly and safely into the complete machine.
These Installation Instructions are a part of the product. The safety-
relevant information should be taken over for the documentation of
the complete machine.
With customer-specific project pumps (pump types which begin
with “PL” or “PML”), there may be differences from the Installation
Instructions.
1.2 Warnings
Warnings in the Installation Instructions are marked by the hazard
symbol, the keywords, and the color. These features provide
information about the extent of the hazard.
DANGER
This indicates a dangerous situation that will directly cause death
or serious injury if not prevented.
WARNING
This indicates a dangerous situation that may cause death or
serious injury if not prevented.
CAUTION
This indicates a dangerous situation that may cause moderate or
slight injuries if not prevented.
NOTICE
This indicates a situation that may cause damage to property if
not prevented.
Content
Storage location
Project pumps

Installation Instructions FK 1100 General
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1.3 Disclaimer
The manufacturer accepts no liability for damage or malfunctions
that are caused by non-compliance with the Installation Instruc-
tions.
The manufacturer accepts no liability for damage or malfunctions
that are caused by modifications to or conversions of the device or
by improper handling.
The manufacturer accepts no liability for damage or malfunctions
that are caused by using spare parts or accessories that are not
approved by the manufacturer.
1.4 Manufacturer’s address
KNF Flodos AG
Wassermatte 2
6210 Sursee, Switzerland
Phone [phone]
Fax[phone]
www.knf.com
1.5 Supporting documents
The listed documents must also be observed. The valid versions
are available at www.knf.com/downloads.
▪Data sheet
▪3D model
The following must also be observed:
▪Local T&Cs
▪Sales documents and agreement between KNF and the cus-
tomer
▪Drive specification

Safety Installation Instructions FK 1100
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2 Safety
2.1 Intended use
The pump is intended solely for the following uses:
▪Transferring liquids and gases
▪For operation in accordance with the operating parameters
specified in the technical data of the supporting documents
2.2 Reasonably foreseeable misuse
The pump must not:
▪be operated in an explosive atmosphere
▪be used to transfer explosive media
▪be used to transfer media whose compatibility with the pump
head, valves, diaphragm, and seals has not been proven
2.3 Responsibility of the user
The user is responsible for ensuring that the safety precautions in
these Installation Instructions are complied with. Applicable safety,
accident prevention, and environmental protection regulations must
be complied with.
2.4 Product-specific risks
Remaining risks that were determined in a risk assessment are
described in this section. Safety precautions and warnings in this
section and in the other sections of the Installation Instructions
must be observed to prevent dangerous situations.
DANGER
Danger of injuries and damage to property due to dangerous
substances
Poisoning and chemical burns or unintended reactions caused by
leaking dangerous substances
➢Observe the safety data sheets of the transferred media.
➢Before transferring a medium, check whether it can be
transferred safely in the specific application case.
➢Ensure that the system is not subject to any risks of explo-
sion –not even under extreme operating conditions (tem-
perature, pressure) or in case of malfunctions.
➢Ensure the pump is used only by suitably trained, skilled
employees.
➢Clarify the chemical resistance of the head materials.
➢Check that the pump and the system do not leak at the op-
erating temperature of the transferred medium.
➢Check the pump for damage regularly.
➢Operate the pump only when you are sure it has no tech-
nical malfunctions.
➢Operate the pump in accordance with the technical data.
➢Work on the pump or fluid circulation system only after they
have been decontaminated and/or a decontamination decla-
ration is present.

Installation Instructions FK 1100 Safety
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DANGER
Danger of injuries and damage to property due to leaks at the
interfaces to the pump head
Poisoning and chemical burns or unintended reactions caused by
leaking dangerous substances
➢Wear personal protective equipment.
➢Connect the pump correctly.
➢Operate the pump only when you are sure it has no tech-
nical malfunctions.
➢Operate the pump in accordance with the technical data.
DANGER
Danger of injuries and damage to property due to uncon-
trolled flow while the pump is not in operation
Poisoning and chemical burns or unintended reactions caused by
leaking dangerous substances
➢Construct the fluid system so that the operating pressure at
the pressure side of the pump is higher than at the suction
side.
➢Install a shut-off valve in the fluid circulation system.
The risk analysis indicates a risk of explosion from materials and
substances.
DANGER
Danger of injuries and damage to property due to an explo-
sion in the pump
The pump housing is made from aluminum. If the pump dia-
phragm is damaged, medium can accumulate in the housing and
form hydrogen (especially with acids and lyes). This could cause
an explosion in the pump housing.
➢Check and monitor the reactivity of the medium with alu-
minum.
➢No flammable materials in the direct vicinity of the pump or
piping
The pump housing is designed to withstand pressure surges
caused by explosions. The probability of a fault that would cause
an explosion is deemed to be low. When installed in the system,
the risks in the complete system must be assessed.

Safety Installation Instructions FK 1100
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DANGER
Danger of injuries and property damage caused by an explo-
sion in the connection lines and in the pump
Evaporation of flammable liquids
➢When flammable liquids are transferred, an explosive at-
mosphere can form in the pump and in the lines during fill-
ing and emptying.
➢With the hoses that are used, pay attention that no electro-
static charges can form (use conductive materials, ground-
ing and potential equalization).
➢The hoses and piping that are used must be able to with-
stand the expected pressure of explosion.
DANGER
Danger of injuries and property damage caused by the pump
exploding
If the pump has not been used or has been stored for some time,
residual medium may evaporate and, together with oxygen, form
an explosive atmosphere.
➢If the pump has not been used for some time or is stored,
empty the pump and rinse with neutral medium to prevent a
subsequent reaction.
WARNING
Danger of injuries and property damage caused by leaks to
the environment
Flammable materials
➢Keep flammable materials away from the direct vicinity of
the pump and piping.
2.5 Customer service and repairs
All repairs to the pumps must be carried out by the responsible
KNF customer service team.
Use only genuine parts from KNF for servicing work.

Installation Instructions FK 1100 Installation
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3 Installation
WARNING
Danger from incorrect installation
Injuries or damage to property from leaking media
➢After installation, check the system for leaks with a safe
medium.
➢Observe the requirements for intended use.
➢Take precautions in the design of the end device so that
leaking liquids cannot come into contact with live compo-
nents.
➢Use only connections that are specified in the data sheet.
Do not use NPT threads or sealing tape, as cracks can
occur at the plastic connections.
The following requirements apply to all activities described in this
section:
3.1 Installation location
The installation location must:
▪protect the pump against immersion
▪keep aggressive and flammable liquids and vapors away
▪allow hoses to be connected without tensile or bending stress
▪take account of cooling the pump drive
▪ensure that any leaks can be handled
▪have appropriate precautions if flammable media are used
3.2 Mechanical mounting
▪Protect the product against impacts, knocks, and strong vibra-
tions.
▪Please refer to the product data sheet for dimensions, installa-
tion positions, and fluid connections.
CAUTION
Danger due to loss of stability
Injuries caused by the pump toppling over
➢Wear safety shoes with steel caps.
➢When the pump is installed in the machine, secure it with
screws or clamps.
➢When attaching accessories, make sure that the pump can-
not topple over.

Installation Installation Instructions FK 1100
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3.3 Connecting the fluid system
Use suitable means to check the fluid connection for leaks.
For more information regarding dimensions, please refer to the
data sheet.
3.4 Electrical connection
For terminal assignment, output data, and control requirements,
please refer to the data sheet.
Observe the regulatory requirements for electrical installations:
▪Overload protection and separating protective devices
▪Contact protection and additional insulation
▪Ground connections
▪Protection against vibrations, tensile stress, and corrosion
WARNING
Danger of electric shock
If the pump is not installed correctly, there is a risk of electric
shock.
➢The electrical installation of the pump must be carried out
by a trained specialist who has relevant credentials.

Installation Instructions FK 1100 Initial start-up
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4 Initial start-up
The product must not be started up until it has been ensured that
the machine in which the product is to be installed meets the
requirements of the Machinery Directive 2006/42/EC, if applicable.
WARNING
Danger that the fluid system could rupture due to excess
pressure
The pump builds up pressure. With a closed system, the max.
permitted operating pressure can be exceeded. This may cause
injuries to personnel, or damage to the pump or the system.
➢Prevent operation against a closed system.
➢In the case of parts that are in contact with the fluid, use
only those that are designed to withstand at least the op-
erating pressure of the pump.
➢If necessary, take suitable measures to limit the maximum
system pressure.
CAUTION
Danger of unexpected chemical reactions with water
Residues of water in the pump that come from testing in the
factory may react with the transferred medium.
➢Before starting the pump for the first time, rinse it with a
medium that is uncritical as regards water.

Initial start-up Installation Instructions FK 1100
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CAUTION
Danger from hot surfaces
The pump becomes hot during operation. Burns from hot surfaces
or injuries from uncontrolled movements are possible.
➢Do not touch the pump while it is operating.
➢Ensure a sufficient supply of cool air and keep a safe dis-
tance between the pump and neighboring components.
➢Operate the pump in accordance with the technical data.
➢If the temperature of the medium is above 50°C, take safety
precautions to prevent burns of fluid components.
Before switching on the pump, verify the following:
▪All hoses are attached properly.
▪Pump is mechanically fixed in place.
▪Specifications of the power supply correspond with the data on
the pump’s type plate.
▪Pump outlet is not blocked.
▪All cables are attached properly.
▪Contact protection for electrical connections and moving parts
is installed.
CAUTION
Danger of scalding from hot medium leaks
In the terminal system, check the fluid system for leaks at the
operating temperature of the medium.
CAUTION
Danger from rotating parts
The pump must not be operated with the housing cover open.

Installation Instructions FK 1100 Maintenance
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5 Maintenance
Ask your KNF representative about the availability of spare parts
for this product.
Use only genuine parts from KNF for servicing work.
5.1 Cleaning
WARNING
Danger due to dangerous substances in the pump
Depending on the medium transferred, chemical burns or poison-
ing is possible.
➢If necessary, wear protective equipment, such as safety
gloves.
➢Work on the pump or fluid circulation system only after
they have been decontaminated and/or a decontamination
declaration is present.
➢Rinse the pump with a neutralizing liquid and then pump it
empty.
WARNING
Danger from medium spraying in the environment
Due to pressure in the pump and adjacent parts, medium can
spray out if hydraulic parts are manipulated or opened.
➢Always depressurize the hydraulic parts of the system be-
fore carrying out any work.
➢Disconnect the pump from the power supply and make
sure that it cannot be switched on again inadvertently.
Clean the pump.
Clean and dry the parts with a cloth. Do not use solvents for
cleaning, as they can harm plastic parts.
If compressed air is available, blow out the components.

Maintenance Installation Instructions FK 1100
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5.2 Preparing for dismantling
1. Rinse the pump with a suitable neutralizing liquid and make
sure that there are no dangerous substances left in the pump
(see warnings above).
2. Pump the unit empty.
3. Disconnect electrical connections.
4. Remove hoses from pump head.
Qty
Tools
1
Torx screwdriver T30
1
Slotted screwdriver size 0
1
Allen key size 4mm
Table 1
5.3 Dismantling the motor
To clean the pump or replace the elastomer parts, the motor does
not necessarily have to be dismantled. In this case, continue with
Section 5.5.
1. Undo the four screws (1).
2. Carefully remove the motor from the pump housing.
3. Remove the O-ring (3) from the motor flange (2).
5.4 Mounting the motor
1. Insert the O-ring (3) into the motor flange (2).
Place the motor on the pump housing. Make sure that the
coupling parts engage properly and that the star-shaped damp-
ing element is installed.
Tighten the four screws (1) to 2.5 Nm.
Tools
Figure 1: Motor

Installation Instructions FK 1100 Maintenance
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Figure 2: Head parts
5.5 Dismantling the pump head
Undo the eight head screws (1) and remove the complete head
from the pump housing.
Remove the head plate (2) from the connecting plate (6).
Remove the resonating diaphragm (5), both O-rings (4) and
Cellasto (3) from the head plate (2).
Remove the three intermediate plates (9) according to Figure 3
from the connecting plate (6) using a slot screwdriver (size 0).
Remove the six O-rings (7) and anchor valves (8) from the
connecting plate (6). Note: Do not use sharp objects to remove
the O-rings to avoid damaging them. Use compressed air to
blow out the O-rings.
Undo the three diaphragms (10) by hand.
Remove the three insert rings (11) from the pump housing.
Clean all the parts, making sure that all residues are removed.
Then blow them out with compressed air and dry them.
To ensure maximum tightness after opening the pump head, we
recommend replacing the rubber parts, diaphragms (10), anchor
valves (8), O-rings (7), oscillating diaphragm (5), and O-rings (4).
Cleaning the parts
Wipe the following items with a cloth and then blow them out
with compressed air: O-Rings resonating diaphragm (4), reso-
nating diaphragm (5), valve O-rings (7), anchor valves (8), and
diaphragms (10).
Blow out the connecting plate (6) and intermediate plate (9)
with compressed air.
1 Head screws
2 Head plate
3 Cellasto
4 O-ring resonating diaphragm
5 Resonating diaphragm
6 Connecting plate
7 O-rings valves
8 Anchor valves
9 Intermediate plate
10 Diaphragm
11 Insert ring
Figure 3: Dismantling the intermediate
plate

Maintenance Installation Instructions FK 1100
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Figure 5: Installing the intermediate
plate
Figure 6: Installing the resonating diaphragm
5.6 Assembling the pump head
Insert the three insert rings (11) in the pump housing; see
Figure 2.
For easier installation of the diaphragms (10), turn the connect-
ing rod to top dead center, beginning with head I. Tighten the
diaphragms well (10) by hand. Repeat the steps for heads II
and III.
For head II, press the middle diaphragm (10) to bottom dead
center with your thumb.
Place the head plate (2) according to Figure 4.
Insert the Cellasto (3) and the two O-rings (4) into the head
plate (2).
Place the resonating diaphragm (5) on the head plate (2)
according to Figure 6. Make sure that the cut-out in the reso-
nating diaphragm (5) and the cams in the head plate (2) are
positioned correctly.
Insert the six O-rings (7) and anchor valves (8) in the connect-
ing plate (6) according to Figure 5.
Click the three intermediate plates (9) into the connecting plate
(6).
Place the connecting plate (6) on the head plate (2).
Place the complete head on the pump housing. Make sure that
the head sits properly to ensure the desired transfer direction
(direction of arrow).
Insert the eight head screws (1) in the head plate (2), but
tighten them only slightly for now.
Tighten the four inside head screws (1) in a diagonal sequence
by one rotation each.
Tighten the four outside head screws (1) in a diagonal se-
quence by one rotation each.
Repeat steps 12. and 13. until all the head screws (1) are
tightened to 3.5 Nm. This procedure is important to ensure that
the diaphragm is compressed equally, and the pump is leak-
tight.
Figure 4: Head installation

Installation Instructions FK 1100 Maintenance
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CAUTION
Caution, escaping liquid
After assembly, the pump may not be leak-tight due to incorrect
assembly, damaged or soiled seal faces, or other reasons.
➢Run the pump for several minutes with a harmless medium
at maximum operating pressure.
➢Check that the pump is leak-tight.
5.7 Mounting the motor
If the motor was dismantled:
For correct installation of the motor, refer to Section 5.4.

Overpressure protection .27 Installation Instructions FK 1100
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Figure 7: Overpressure protection
6 Overpressure protection .27
Overpressure protection is available as an option and can be
retrofitted by KNF.
6.1 Dismantling and cleaning
If the motor is to be dismantled, refer to Section 5.3.
To prepare for dismantling, refer to Section 5.2.
Qty
Tools
1
Allen key size 4mm
1
Torx screwdriver T10
Table 2
1. Unscrew the setscrew (2) completely and remove it to relieve
the pressure spring (3).
Note: Do not adjust the hex nut (1), as this defines the pres-
sure and position for installation.
2. Undo the four head screws (4) and remove the top part (5).
3. Remove the pressure spring (3), washer (6), support (7),
sliding disk (8), and diaphragm (9).
It is recommended that you replace the diaphragm (9).
Cleaning the overpressure protection
4. Clean and dry the parts with a cloth. Do not use solvents for
cleaning, as they can harm plastic parts.
5. If compressed air is available, blow out the components.
6.2 Assembling
1. Insert the diaphragm (9) in the connecting plate.
2. Place the parts on the diaphragm (9) in the following order.
Sliding disk (8), support (7), and washer (6).
3. Place the top part (5) on the connecting plate.
4. Tighten the four head screws (4) in a diagonal sequence to 0.7
Nm.
5. Insert the pressure spring (3) and turn the setscrew (2) to its
original position. Secure with the hex nut (1).
If the motor was dismantled, refer to Section 5.4.
NOTICE
The pressure setting on the overpressure relief valve must be
checked.
Tools
1 Hex nut
2 Setscrew with bolt
3 Pressure spring
4 Head screws .27
5 Top part .27
6 Washer
7 Support
8 Sliding disk
9 Diaphragm .27

Installation Instructions FK 1100 Overpressure protection .27
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CAUTION
Caution, escaping liquid
After assembly, the overpressure protection may not be leak-tight
due to incorrect assembly, damaged or soiled seal faces, or other
reasons.
➢Run the pump for several minutes with a harmless medium
at maximum operating pressure.
➢Check that the pump is leak-tight.

Rectifying transfer problems Installation Instructions FK 1100
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7 Rectifying transfer problems
Symptom
Cause
Remedy
Pump does not
work; no movement
or sounds are de-
tectable.
No or incorrect control
Check that voltage and signal form comply
with the specification.
Pump does not
work; drive be-
comes very hot.
Motor is controlled with an
incorrect signal.
Check that voltage and signal form comply
with the specification.
The pump does not
prime, or vacuum is
insufficient.
External valve is closed.
Check external valve.
Counterpressure on pres-
sure side is too high.
Change the pressure conditions on the
pressure side.
Particles in the pump head
Rinse the pump head.
Use a preventive preliminary filter.
Pump does not
transfer.
External valve is closed, or
filter is clogged or too small.
Check external valves and filter.
Connections or hoses are
blocked.
Check connections and hoses.
Remove blockage.
Flow rate is insuffi-
cient or unstable.
Incorrect control
Check that voltage and signal form comply
with the specification.
Cross-section of hydraulic
hoses or connectors too
narrow or restricted
Disconnect the pump from the system and
determine performance data.
Remove restriction (e.g. valve), if neces-
sary.
If applicable, use larger-diameter hoses or
connectors.
Higher counterpressure in
the system than assumed
for the design
Contact KNF representative.
Particles in the pump head
Rinse the pump head.
Use a preventive preliminary filter.
Replace pump head.
Pump has reached the end
of its service life.
Replace the pump.
Leak on pump head
Damage to the valve O-
rings
Replace the O-rings.
Diaphragm damaged
Replace the diaphragm.
Resonating diaphragm
damaged
Replace resonating diaphragm.
If the malfunction cannot be rectified, contact your local KNF
representative (www.knf.com).