KNF FP25 User manual

FP25 / FP1.25
INSTALLATION INSTRUCTIONS
DIAPHRAGM PUMP
Before operating the pump and the accessories, please read the Installation Instructions
and safety precautions.

Installation Instructions FP 25 Contents
KNF Flodos 338092_MA_FP25_EN_00
3
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 7
3Installation.................................................................................8
3.1 Installation location 8
3.2 Mechanical mounting 9
3.3 Connecting the fluid system 9
3.4 Electrical connection 9
4Initial start-up..........................................................................10
5Maintenance............................................................................12
5.1 Cleaning 12
5.2 Preparing for dismantling 13
5.3 Dismantling the pump head 13
5.4 Assembling the pump head 13
6Rectifying transfer problems.................................................15
7Spare parts..............................................................................16
8Returning the pump................................................................18

General Installation Instructions FP 25
KNF Flodos 338092_MA_FP25_EN_00
4
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 infor-
mation 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 seri-
ous 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 FP 25 General
KNF Flodos 338092_MA_FP25_EN_00
5
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.
▪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 FP 25
KNF Flodos 338092_MA_FP25_EN_00
6
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 de-
scribed in this section. Safety precautions and warnings in this sec-
tion 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 FP 25 Safety
KNF Flodos 338092_MA_FP25_EN_00
7
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.
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 Installation Instructions FP 25
KNF Flodos 338092_MA_FP25_EN_00
8
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.
UNF1/4”-28 thread is recommended. 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
Mounting orientation
The following points are recommended for optimal filling and
venting of the pump head.
▪horizontal mounting position
▪Filling / emptying pump with nominal rpm (nominal voltage).
Figure 1: Horizontal orientation

Installation Instructions FP 25 Installation
KNF Flodos 338092_MA_FP25_EN_00
9
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.
Following mounting options are available
▪Groove (1) for mounting of clip (for detail information and avail-
ability contact KNF).
▪Holes (2) for PT screws KA30. Hole spacing and depth of holes
see data sheet FP 25. Torque 0.35Nm.
3.3 Connecting the fluid system
Use suitable means to check the fluid connection for leaks.
Connections 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 accord-
ing to current value on the type plate. The pumps must be
fused individually.
▪Contact protection and additional insulation
▪Ground connections
▪Protection against vibrations, tensile stress, and corrosion
For detailed information about control, please refer to the drive
specification (available from your local KNF dealer).
Figure 2: Mounting

Initial start-up Installation Instructions FP 25
KNF Flodos 338092_MA_FP25_EN_00
10
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 re-
quirements 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 oper-
ating 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 fac-
tory may react with the transferred medium.
➢Before starting the pump for the first time, rinse it with a me-
dium that is uncritical as regards water.
VORSICHT
Danger of automatic restart
Pumps with brushless DC-motor have a thermal overload protec-
tion with automatic recovery to protect the motor from overheat-
ing. After cooling down the motor starts automatically.
➢Ensure that this does not cause a hazardous situation

Installation Instructions FP 25 Initial start-up
KNF Flodos 338092_MA_FP25_EN_00
11
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 op-
erating temperature of the medium.

Maintenance Installation Instructions FP 25
KNF Flodos 338092_MA_FP25_EN_00
12
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.

Installation Instructions FP 25 Maintenance
KNF Flodos 338092_MA_FP25_EN_00
13
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 in horizontal mounting position with nomi-
nal rpm (nominal voltage). See also Chapter Fehler! Verweis-
quelle konnte nicht gefunden werden..
3. Disconnect electrical connections.
4. Remove hoses from pump head.
Qty
Tools
1
Torx screwdriver T10
1
Torx screwdriver T6
Table 1
5.3 Dismantling the pump head
Undo the four head screws (1) and remove the complete head
(2) from the pump housing (4).
Carefully grip the diaphragm (3) and remove by turning coun-
terclockwise.
Rotate head (2) like shown in Figure 4.
Remove the intermediate plate (5) from the connecting plate
(9).
Remove both gaskets (6) and both valves (7) from the con-
necting plate (9).
Undo the six damper screws (8) and remove them from the
connecting plate (9)
Remove resonating diaphragm (10) and dampening element
(11) form the head plate (12).
To ensure maximum tightness after opening the pump head, we
recommend replacing all elastomer parts. See chapter 7 for spare
parts kit.
Clean all the parts with a cloth, making sure that all residues
are removed and blow them off with compressed air.
5.4 Assembling the pump head
Insert the diaphragm (3) and tighten it well by hand.
By slightly pressing on the diaphragm, the ridge on the under-
side of the diaphragm can be positioned into the groove of the
housing.
Place the head plate (12) according to Figure 4.
Tools
Figure 3
Figure 4

Maintenance Installation Instructions FP 25
KNF Flodos 338092_MA_FP25_EN_00
14
Insert the dampening element (11) into the cylindrical part of
the head plate (12).
Place the resonating diaphragm (10) on the head plate (12).
Make sure that the ridge on the underside is properly placed in
the groove of the head plate (12).
Place the connecting plate (9) on the head plate (12). Observe
the direction of the arrow ►on both parts for easier assembly.
The arrows must point in the same direction.
Tighten the six damper screws (8) in a diagonal sequence.
Tightening torque 1.5Nm.
Place both valves (7) and both gaskets (6) into the connecting
plate.
Snap the intermediate plate (5) into the connection plate (9).
Observe the direction of the arrow ►on both parts for easier
assembly. The arrows must point in the same direction.
Place complete head (2) onto the pump housing (4).
Insert the four head screws (1) and tighten the screws in a di-
agonal sequence. Tightening torque 0.4Nm.
Re-connect the hoses to the pump head.
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.
Figure 6: Direction of arrow
Figure 5

Installation Instructions FP 25 Rectifying transfer problems
KNF Flodos 338092_MA_FP25_EN_00
15
6 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 repre-
sentative (www.knf.com).

Spare parts Installation Instructions FP 25
KNF Flodos 338092_MA_FP25_EN_00
16
7 Spare parts
Spare parts kit “elastomer”FP25
Pos
Name
Material
Order-No.
Pieces
in set
Pieces
in set
Pieces
in set
Kit _P Elastomer FP25
341841
Kit _P.51 Elastomer FP25
341842
Kit _T Elastomer FP25
341843
10
Diaphragm
EPDM
-
1
1
PTFE
1
-
-
20
Valve
EPDM
-
2
2
FFKM
2
-
-
30
Gasket
EPDM
-
2
2
FKM
2
-
-
40
Resonating diaphragm
EPDM
-
1
1
PTFE
1
-
-
50
Dampening element
Sylodyn
1
1
1
Spare parts kit “elastomer” FP1.25
Pos
Name
Material
Order-No.
Pieces
in set
Pieces
in set
Pieces
in set
Kit _P Elastomer FP1.25
341844
Kit _P.51 Elastomer FP1.25
341845
Kit _T Elastomer FP1.25
341846
10
Diaphragm
EPDM
-
1
1
PTFE
1
-
-
20
Valve
EPDM
-
2
2
FFKM
2
-
-
30
Gasket
EPDM
-
2
2
FKM
2
-
-
40
Resonating diaphragm
EPDM
-
1
1
PTFE
1
-
-
50
Dampening element
Sylodyn
1
1
1
Figure 7: Spare parts kit “elastomer”FP25
Figure 8: Spare parts kit “elastomer” FP1.25

Installation Instructions FP 25 Spare parts
KNF Flodos 338092_MA_FP25_EN_00
17
Spare parts kit “plastic”FP25
Pos
Name
Material
Order-No.
Pieces
in set
Pieces
in set
Kit R_ Plastic FP25
341847
Kit R_.51 Plastic FP25
341848
10
Intermediate plate
PPS GF40%
1
1
20
PT Screw 30x10
Inox
6
6
30
Connection Plate
PPS GF40%
1
1
40
Head plate
PA GF40%
1
1
50
PT Screw 22x12
Inox
4
4
Spare parts kit “plastic” FP1.25
Pos
Name
Material
Order-No.
Pieces
in set
Pieces
in set
Kit R_ Plastic FP1.25
341860
Kit R_.51 Plastic FP1.25
341861
10
Intermediate plate
PPS GF40%
1
1
20
PT Screw 30x10
Inox
6
6
30
Connection Plate
PPS GF40%
1
1
40
Head plate
PA GF40%
1
1
50
PT Screw 22x12
Inox
4
4
60
Clamping ring DN4/6
PP
2
2
70
Connecting nut DN4/6
PP
2
2
Figure 9: Spare parts kit “plastic”FP25
Figure 10: Spare parts kit “plastic” FP1.25

Returning the pump Installation Instructions FP 25
KNF Flodos 338092_MA_FP25_EN_00
18
8 Returning the pump
KNF undertakes to repair the pump only on condition that the
customer provides a certificate of the pumped medium and
cleaning of the pump. For this, please follow the instructions on
www.knf.com/repairs.
Please contact your KNF sales representative directly if you
need additional support for your return service.

www.knf.com