KNF N96 User manual

N96
TRANSLATION OF ORIGINAL OPERATING AND
INSTALLATION INSTRUCTION
ENGLISH
KNF 316836-316838 01/20 EN-US
OEM
Notice!
Before operating the pump and the accessories, read the operating and installation instructions and observe
the safety notices!
DIAPHRAGM PUMP

Index
1 About this document ......................................................... 3
2 Use ................................................................................... 5
3 Safety................................................................................ 6
4 Technical data .................................................................. 8
5 Design and function ........................................................ 11
6 Transport ........................................................................ 12
7 Installation and connection ............................................. 13
8 Operation ........................................................................ 22
9 Servicing ......................................................................... 25
10 Troubleshooting .............................................................. 30
11 Spare parts and accessories .......................................... 32
12 Returns ........................................................................... 33
KNF Neuberger GmbH
Alter Weg 3
79112 Freiburg
Germany
Tel. [phone]
Fax. [phone]
www.knf.com

Diaphragm pump N96 About this document
Translation of Original Operating and Installation Instruction, English, KNF 316836-316838 01/20 3
1 About this document
1.1 Using the operating and installation instructions
The operating and installation instructions are part of the pump.
àIn the event of uncertainties with regard to the content of the operating
and installation instructions, please contact the manufacturer (contact
data: see www.knf.com). Please have the type designation and serial
number of the pump ready.
àRead the operating and installation instructions before you commission
the pump.
àGive the operating and installation instructions to the next owner.
àKeep the operating and installation instructions within reach at all
times.
Project pumps For customer-specific project pumps (pump models that begin with "PJ" or
"PM"), there may be deviations from the operating and installation instruc-
tions.
àFor project pumps, also observe the agreed specifications.
1.2 Exclusion of liability
The manufacturer assumes no liability for damages and malfunctions re-
sulting from failure to observe the operating and installation instructions.
The manufacturer assumes no liability for damages and malfunctions re-
sulting from changes or modifications to the device and improper handling.
The manufacturer assumes no liability for damages and malfunctions re-
sulting from impermissible spare parts and accessories.
1.3 Symbols and markings
Warning notice
WARNING
A notice that warns you of danger is located here.
Possible consequences of a failure to observe the
warning notice are specified here. The signal
word, e.g., warning, indicates the danger level.
àMeasures for avoiding the danger and its
consequences are specified here.
Danger levels
Signal word Meaning Consequences if not
observed
DANGER warns of immediate
danger
Death or serious injury
or serious damage will
result.
WARNING warns of possible dan-
ger
Death or serious injury
or serious damage is
possible.
CAUTION warns of a possibly
dangerous situation
Minor injuries or dam-
age is possible.
Tab.1

About this document Diaphragm pump N96
4 Translation of Original Operating and Installation Instruction, English, KNF 316836-316838 01/20
Explanations of pictograms
Pictogram Meaning
General warning symbol
Warning of hot surface
Warning of electrical voltage
Warning of explosive materials
Warning of poisonous substances
Warning of hand injuries through crushing
Observe the operating instructions
Tab.3
Other notices and symbols
àAn activity to be carried out is specified here (a step).
1. The first step of an activity to be carried out is specified here.
Follow other sequentially numbered steps.
This symbol indicates important information.

Diaphragm pump N96 Use
Translation of Original Operating and Installation Instruction, English, KNF 316836-316838 01/20 5
2 Use
2.1 Proper use
The pumps are intended exclusively for transferring gases and vapors.
Responsibility of the owner
Operating parameters and
conditions
Only install and operate the pumps in accordance with the operating pa-
rameters and conditions described in Chapter 4 Technical data.
Only pumps that are fully assembled and in the condition as delivered may
be operated.
Make sure that the installation location is dry and that the pump is pro-
tected against rain, splash, gushing, and drip water as well as from other
contaminants.
Check the tightness of the connections between the pipes of the applica-
tion and the pump (or the connection of the pump) at regular intervals.
Leaky connections carry the risk of releasing dangerous gases and vapors
from the pump system.
Requirements for the transferred
medium
Before transferring a medium, check whether the medium can be trans-
ferred danger-free in the specific application.
Before using a medium, check the compatibility of the media-contacting
components (see 4 Technical data) with the medium.
Risk of dangerous gas mixtures during pump operation if diaphragm
breaks: Depending on the medium being transferred, breakage of the di-
aphragm can result in a dangerous mixture if the medium mixes with the
air in the compressor housing or the surroundings.
Only transfer gases that remain stable under the pressures and tempera-
tures that arise in the pump.
2.2 Improper use
The pumps are not allowed to be operated in explosive atmospheres.
The pumps are not suitable for delivering:
§Dusts
§Fluids
§Aerosols
§Biological and microbiological substances
§Fuel
§Explosive substances and flammable materials
§Fibers
§Oxidants
§Food
Pumps that can generate both a vacuum and overpressure must not be
used for the simultaneous generation of a vacuum and overpressure.
This function can be made possible on a project basis following consulta-
tion with KNF Customer Service.
No overpressure may be applied to the suction side of the pump.
This function can be made possible on a project basis following consulta-
tion with KNF Customer Service.

Safety Diaphragm pump N96
6 Translation of Original Operating and Installation Instruction, English, KNF 316836-316838 01/20
3 Safety
Observe the safety instructions in the Chapters 7 Installation and
Connection and 8.1 Operation.
The pumps are built in accordance with the generally recognized rules of
engineering and the occupational health and safety and accident preven-
tion regulations. Nevertheless, dangers can arise during their use that lead
to injuries to the user or third parties or to damage to the pump or other
property.
Only use the pumps if in technically perfect condition, in accordance with
their intended use, in a safety-conscious and danger-conscious manner
and in compliance with the operating and installation instructions.
The components that are to be connected to the pumps must be designed
according to the pneumatic data of the pumps.
When connecting the pumps to the electrical mains, observe the corre-
sponding safety rules.
Personnel Make sure that only trained and instructed personnel or qualified personnel
work on the pumps. This applies, in particular, to assembly, connection
and servicing work.
Make sure that the personnel have read and understood the operating and
installation instructions, especially the Chapter Safety.
Working in a safety conscious
manner
Observe the regulations on accident prevention and safety during all work
on the pumps and during operation.
Avoid contact with the heads and housing parts as the pump heats up dur-
ing operation.
When working on the pump, make certain that the pump is disconnected
from the mains and is de-energized.
Make certain that no dangers arise from flows when gas connections are
open, from the effects of noise or from hot, corrosive, dangerous and envi-
ronmentally hazardous gases.
Make sure that EMC-compliant installation of the pump is guaranteed at all
times and that no danger situation can arise as a result.
Handling of hazardous media Upon breakage of the diaphragm and/or leaks, the transferred medium
mixes with the air in the surroundings and/or in the pump housing. Make
sure that a dangerous situation cannot arise as a result.
When pumping hazardous media, observe the safety regulations for the
handling of these media.
Handling of combustible media Take heed that the pumps are not designed to be explosion-proof.
Make certain that the temperature of the medium is always sufficiently be-
low the ignition temperature of the medium so as to prevent ignition or ex-
plosion. This also applies for abnormal operating situations.
Bear in mind that the temperature of the medium increases when the
pump compresses the medium.
Therefore, make certain that the temperature of the medium also remains
sufficiently below the ignition temperature of the medium even when it is
compressed to the maximum permissible operating pressure of the pump.
The maximum permissible operating pressure of the pump is stated in
Chapter 4 Technical data.
Make certain that the permissible ambient temperature (4 Technical data)
is not exceeded.
If applicable, also take into consideration external energy sources (e.g. ra-
diation sources) that could additionally heat the medium.
In case of doubt, contact KNF Customer Service.

Diaphragm pump N96 Safety
Translation of Original Operating and Installation Instruction, English, KNF 316836-316838 01/20 7
Environmental protection Store and dispose of all replacement parts in accordance with the environ-
mental regulations. Observe the respective national and international regu-
lations. This applies in particular to parts that are contaminated with toxic
substances.
EU/EC directives/standards With respect to the Machinery Directive 2006/42/EC, the pumps are partly
completed machinery and are, therefore, to be regarded as not ready for
use. Partly completed machinery may not be commissioned until it has
been determined that the machine into which the partly completed machin-
ery is to be installed complies with the provisions of the Machinery Direc-
tive 2006/42/EC. The following fundamental requirements of Annex I of Di-
rective 2006/42/EC (general principles) are applied and observed:
§General principles no. 1
As these partly completed machines are built-in devices, the mains con-
nections and equipment for disconnecting and switching off the partly com-
pleted machinery as well as overcurrent and overload protection gear must
be considered when mounting.
Furthermore, protection against contact with moving and hot parts, if
present, must be provided during installation.
The pumps comply with Directive 2011/65/EU.
The following harmonized standards are met:
§DIN EN 50581
§DIN EN 61000-6-2/3
Customer service and repairs The pumps are maintenance-free. KNF does, however, recommend peri-
odically inspecting the pumps for conspicuous changes in the noises and
vibrations.
Only have repairs to the pumps performed by the responsible KNF Cus-
tomer Service.
Housings with live components may only be opened by specialist person-
nel.
Use only original parts from KNF during servicing work.

Technical data Diaphragm pump N96
8 Translation of Original Operating and Installation Instruction, English, KNF 316836-316838 01/20
4 Technical data
Technical data
Pump materials
Assembly Material
KN
Material
KT
Pump head PPS PPS
Diaphragm EPDM PTFE-coated
Valves FKM FKM
Tab.5 Pump materials KN/KT variant
Pneumatic values
N96KNDC-B-M
Parameter Value
Max. permissible operating pressure
[bar rel*]
2.5
Ultimate vacuum [mbar abs.] <100
Flow rate at atm. pressure [l/min]** 8.5 ± 10%
Tab.7
*Bar rel related to 1013 hPa
**Liters in standard state (1013 hPa, 20°C)
N96KTDC-B-M
Parameter Value
Max. permissible operating pressure
[bar rel*]
2.5
Ultimate vacuum [mbar abs.] <130
Flow rate at atm. pressure [l/min]** 7.0 ± 10%
Tab.9
*Bar rel related to 1013 hPa
**Liters in standard state (1013 hPa, 20°C)
Pneumatic connections
Pump type Value Value
N96KNDC-B-M G1/8 NPT 1/8
N96KTDC-B-M G1/8 NPT 1/8
Tab.11

Diaphragm pump N96 Technical data
Translation of Original Operating and Installation Instruction, English, KNF 316836-316838 01/20 9
Electrical data
Parameter Value
Voltage [V] 24
Frequency [Hz] -
Power P1 [W] KN KT
23 19
Max. permissible mains voltage fluc-
tuations
± 10%
Motor protection class IP20
Rated current consumption [A] KN KT
1,05 0.9
Tab.13
The motor controller has a current limit of max. 2.5ARMS. In the
event of an error, the power of the motor is limited to prevent the
current limit from being exceeded.
Weight
Pump type Value [kg]
N96K_DC-B-M 0.6
Tab.15
Other parameters
Parameter Value
Permissible ambient temperature
[°C]
+ 5 to see Fig. 1
0 if non-condensing (frost-free)
Permissible media temperature [°C] See Fig. 2
Dimensions See Fig. 5, Chapter 7.1 Installing
the pump
Highest permissible relative air hu-
midity of the environment
80% for temperatures to 31°C, de-
creasing linearly to 50% at 40°C.
Maximum installation altitude [m
above sea level]
2000
Gas tightness* of the pump head
(leak rate)
Leak rate
< 6 x 10-3 mbar l/s**
Protection class of pump IP20
Starts against
- Vacuum
- Pressure
KN KT
100
2.5
130
2.5
Tab.17
** The gas tightness of the pump head is no longer ensured after the pump head is
opened or after replacing diaphragms and valve plates. A leak test can be used to
determine whether the original gas tightness is again achieved.
**Values apply for helium leak test

Technical data Diaphragm pump N96
10 Translation of Original Operating and Installation Instruction, English, KNF 316836-316838 01/20
Permissible ambient
temperature
Pressure in
mbar
Pressure in
bar
Fig.1 Permissible ambient temperature
Permissible media
temperature
Pressure in
bar
Pressure in
mbar
Fig.2 Permissible media temperature

Diaphragm pump N96 Design and function
Translation of Original Operating and Installation Instruction, English, KNF 316836-316838 01/20 11
5 Design and function
Design
1Pneumatic pump inlet
2Pneumatic pump outlet
3Motor
4Electrical connection
Fig.3 Design N96
Function of a diaphragm pump
1Outlet valve
2Inlet valve
3Transfer chamber
4Diaphragm
5Eccentric
6Connecting rod
7Pump drive
Fig.4 Function of a diaphragm pump
Diaphragm pumps transfer, compress (depending on the version) and evacu-
ate gases and vapors.
The elastic diaphragm (4) is moved up and down by the eccentric (5) and the
connecting rod (6). In the downwards stroke, it aspirates the gas to be trans-
ferred via the inlet valve (2). In the upwards stroke, the diaphragm presses the
medium out of the pump head via the outlet valve (1). The transfer chamber
(3) is hermetically separated from the pump drive (7) by the diaphragm.

Transport Diaphragm pump N96
12 Translation of Original Operating and Installation Instruction, English, KNF 316836-316838 01/20
6 Transport
General
CAUTION
Personal injury and/or property damage due to in-
correct or improper transport of the pump
In the event of incorrect or improper transport, the
pump can fall down, be damaged or injure per-
sons.
àUse suitable auxiliary means if necessary
(carrying strap, lifting gear, etc.).
àWhere appropriate, wear suitable personal
protective equipment (e.g., safety shoes,
safety gloves).
CAUTION
Risk of injury from sharp edges on the packaging
There is a risk of injury from cutting on the sharp
edges when grabbing corners or when opening
the packaging.
àWhere appropriate, wear suitable personal
protective equipment (e.g., safety shoes,
safety gloves).
àTransport the pump in the original packaging to the installation loca-
tion.
àStore the original packaging of the pump (e.g., for later storage).
àInspect the pump for transport damage after receiving it.
àDocument any transport damage in writing.
àRemove any transport safeguards on the pump prior to commissioning.
Parameter
Parameter Value
Storage temperature [°C] + 5 to + 40
Transport temperature [°C] - 10 to + 60
Permissible humidity (non-condens-
ing) [%]
30 to 85
Tab.19 Transport parameters
Before putting into operation, make sure that the pump has reached
the ambient temperature (4 Technical data).

Diaphragm pump N96 Installation and connection
Translation of Original Operating and Installation Instruction, English, KNF 316836-316838 01/20 13
7 Installation and connection
Install the pumps only in accordance with the operating parameters and
conditions described in Chapter 4 Technical data.
àObserve the safety instructions (see Chapter 3 Safety).
DANGER
Risk of dangerous gas mixtures during pump op-
eration
Depending on the medium being transferred,
breakage of the media-contacting components
can result in a dangerous mixture if the medium
mixes with the air in the compressor housing or
the surroundings.
àBefore using a medium, check the compati-
bility of the media-contacting components
(see 4 Technical data) with the medium.
7.1 Installing the pump
àStore the pump at the installation site prior to installation to bring it up
to the ambient temperature.
CAUTION
Risk of injury from freely rotating shaft end
Touching the pump at the end of the shaft may re-
sult in injury through burning and crushing.
àTake protective measures to safeguard
against touching moving and hot parts.
àWear appropriate personal protective equip-
ment if necessary.
CAUTION
Risk of injury from sharp edges on motor
There is a risk of injury from cutting on the sharp
edges when grabbing the pump on the motor.
àWhere appropriate, wear suitable personal
protective equipment (e.g., safety shoes,
safety gloves).
Mounting dimensions àFor mounting dimensions, see the following illustrations:

Installation and connection Diaphragm pump N96
14 Translation of Original Operating and Installation Instruction, English, KNF 316836-316838 01/20
Fig.5 Mounting dimensions pump series N96
Cooling air supply
WARNING
Danger of burning on hot surfaces
Hot surfaces could occur if the pump overheats.
àWhen installing the pump, make sure that
sufficient cooling air infeed and discharge is
ensured.
Immediate environment of the
hot pump parts
àDuring installation, make sure that no combustible or thermally de-
formable objects are positioned in the immediate environment of the
hot pump parts (head, motor).
Installation location àMake sure that the installation location is dry and that the pump is pro-
tected against rain, splash water, gushing water, dripping water and
other contaminants.
àMake sure that the installation location is accessible for service.
The IP protection class of the pump motor is specified on the type
plate.
àMount the pump at the highest point in the system to prevent conden-
sate from collecting in the pump head.
àProtect the pump from dust.
àProtect the pump from vibration and impact.
Protection against foreign
objects
àProtect the pump against contact and the ingress of foreign bodies.

Diaphragm pump N96 Installation and connection
Translation of Original Operating and Installation Instruction, English, KNF 316836-316838 01/20 15
7.2 Aligning gas connections
Tool Quantity Tool/material
1 Torx TX10 screwdriver
Tab.21
To keep the hose routing as compact as possible, the gas connec-
tions can be oriented according to the system conditions. For this
purpose, the pump head can be rotated in increments of 90° and
mounted.
Fig.6 Aligning gas connections
1. Loosen the four head plate screws (1) and remove the pump head (2)
from the compressor housing.
2. Turn the pump head to the desired position.
Direction of rotation according to the alignment of the gas connec-
tions, see following figure.
Fig.7 Aligning gas connections
AGas connections via motor: Direction of rotation: CW
BGas connections at front: Direction of rotation: CCW
CGas connections at right: Direction of rotation: CW
DGas connections at left: Direction of rotation: CCW
Connection definition of the direction of rotation, see Fig. 8, Fig. 9.
3. Place the pump head (2) on the compressor housing.
4. Tighten the four head plate screws (1) crosswise (tightening torque:
190 – 200Ncm).

Installation and connection Diaphragm pump N96
16 Translation of Original Operating and Installation Instruction, English, KNF 316836-316838 01/20
7.3 Electrical connection
DANGER
Danger to life from electric shock
àOnly have the pump connected by an autho-
rized specialist.
àOnly have the pump connected if the power
supply is disconnected.
àWhen connecting to a power source, observe the applicable standards,
directives, regulations and technical standards.
àInstall in the electrical wiring system a device to disconnect the pump
motor from the electrical supply network (in acc. with EN 60335-1).
àProtect the pump motors in accordance with EN 60204-1 (overcurrent
protection, overload protection).
àThe motors may only be operated in an SELV circuit.
The control lines of the BLDC motor are only protected to a voltage
of up to 1.5 kV (acc. to HBM ESD rating).
If higher ESD requirements are needed, measures are to be pro-
vided by the owner himself.
Refer to the type plate for the maximum current consumption of the
pump.
àIt is recommended that an additional EMERGENCY-STOP device be
installed.
àMount the pumps in such a way that it is not possible to touch the elec-
trically live parts (electrical connection).
The ground potential of the power supply, the interface(s) and the
pump housing are to be at the same potential. Compensating cur-
rents via the motor controller are to be prevented as they may result
in the destruction of the electronics. A sufficient potential equaliza-
tion in accordance with EN 60479-1 is to be dimensioned.
Fastening the connection cables àFasten the connection cables so that
– the cables do not come into contact with movable or hot parts.
– the cables cannot be worn or damaged on sharp corners or edges
– no tensile and pressure forces are exerted on the connection point
of the cables (strain relief)

Diaphragm pump N96 Installation and connection
Translation of Original Operating and Installation Instruction, English, KNF 316836-316838 01/20 17
Connecting the pump
1. Compare the data of the supply voltage with the information on the mo-
tor type plate. See the pump type plate for the maximum current con-
sumption of the pump.
The supply voltage may deviate by maximum +10% or –10% from
the values on the type plate.
2. Electrically connect the pump.
Take into account the direction of rotation according to the orienta-
tion of the gas connections (see Fig. 7, Fig. 9 and Fig. 8).
Control voltage may only be applied if the motor controller is sup-
plied with an operating voltage. The motor controller may otherwise
be damaged.
Ensure the correct polarity. With brushless three-phase motors (in-
dicated by a B at the end of the type designation), incorrect polarity
will result in destruction of the electronics.

Installation and connection Diaphragm pump N96
18 Translation of Original Operating and Installation Instruction, English, KNF 316836-316838 01/20
Connection diagram for motor controller
Motor
Rated voltage [V] 24
Voltage range [V] 9 – 26.4
Coupling: Hirose DF3-6S-2C
Leads connections / PIN assignment
Function Wire lead color Signal name Size PIN
+ Supply voltage Red U+AWG 26 / UL 3266 6
- Supply voltage (0 V) Black U- / GND AWG 26 / UL 3266 1
Input signal for speed control Blue UCtrl AWG 26 / UL 3266 3
Output signal for speed Green USpd AWG 26 / UL 3266 4
Input signal for remote ON/OFF White URmt AWG 26 / UL 3266 2
Input signal for direction of motor rota-
tion
Yellow URot AWG 26 / UL 3266 5
Input signal for speed specification Uctrl PWM signal*
PWM-
signal
PWM frequency range [kHz] 20
[10 … 30]
Input level "high" [V] 5
[2.5…5.5]
Input level "low" [V] 0
[0…0.8]
Duty cycle range, see Fig. 10, Fig. 11 [%] KN KT
30…0 55…0
Input impedance @ 1 kHz [kΩ] ≥ 10
Output signal for speed USpd
Pulses per revolution [-] 6
Pulse duty cycle [%] 50
Output level "high" [V] 5
[2.5…6.0]
Output level "low" [V] 0
[0…0.8]
Max. current carrying capacity [mA] 2
Input impedance @ 1 kHz [kΩ] ≥ 10
Input signal for remote ON/OFF URmt
Input level "high" → Motor ON [V] 5
[2.5…5.5 or open contact]
Input level "low" → Motor OFF [V] 0
[0…0.8]
Input impedance @ 1 kHz [kΩ] ≥ 10
Input signal for direction of motor rotation URot
Standard for pump
Input level "high" → Motor CCW
[V] 5
[2.5…5.5 or open contact]
Not recommended for pump
Input level "low" → Motor CW
[V] 0
[0…0.8]
Input impedance @ 1 kHz [kΩ] ≥ 10
Tab.23 Connection diagram for motor controller N96_DC-B-M
*see Chapter 8.3 Control functions DC-B-M

Diaphragm pump N96 Installation and connection
Translation of Original Operating and Installation Instruction, English, KNF 316836-316838 01/20 19
Fig.8 Connection diagram without external speed setting
Fig.9 Connection diagram with external speed setting
Permissible
control range
Speed
Fig.10 Duty cycle range N96KN_

Installation and connection Diaphragm pump N96
20 Translation of Original Operating and Installation Instruction, English, KNF 316836-316838 01/20
Permissible
control range
Speed
Fig.11 Duty cycle range N96KT_
For expanded permissible duty cycle range, please contact your
KNF Customer Service(contact data: see www.knf.com).
7.4 Pneumatic connection
CAUTION
Personal injury or property damage through
ejected plugs
If not removed, the plugs on the pressure side of
the pump can be ejected during operation by the
resulting overpressure.
àRemove the plugs during installation.
àWear appropriate personal protective equip-
ment.
Connected components àOnly connect components to the pump that are designed for the pneu-
matic data and thermal requirements of the pump. (see Chapter 4
Technical data).
Pressure relief device àProtect the compressors by means of a pressure relief device between
the pressure-side connections of the compressor and the first shut-off
valve.
Pump discharge àIf the pump is being used as a vacuum pump, safely (relating to the
medium and noise) discharge the possibly hot pump discharge via the
pneumatic outlet of the pump.
Decoupling àKNF recommends mechanically decoupling the pump from the pipe
system, e.g., through the use of flexible hoses or pipes. In this way it is
possible to prevent the transfer of possible pump vibrations and noises
to the system.