KNF NPK 25 AC User manual

KNF 121581-121584 08/16
Translation of original Operating and Installation Instructions, english Keep for future use!
Swing Piston Compressors and Vacuum Pumps
NPK 25 AC
NPK 25 DC
Operating and
Installation
Instructions
Read and observe these Oper-
ating and Installation Instruc-
tions!
Contents Page
1. About this document................................................................. 2
2. Use........................................................................................... 3
3. Safety ....................................................................................... 4
4. Technical data.......................................................................... 6
5. Design and function.................................................................. 7
6. Installation and connection....................................................... 8
7. Operation................................................................................ 12
8. Servicing................................................................................. 13
9. Troubleshooting...................................................................... 16
10. Spare parts and accessories.................................................. 18
11. Returns................................................................................... 19
12. Health and safety clearance and decontamination form........ 20
KNF Neuberger GmbH
Alter Weg 3
D-79112 Freiburg
Germany
Tel. [phone]
Fax [phone]
E-Mail: [e-mail]
www.knf.de

About this document Swing Piston Pumps NPK 25
2 Translation of original Operating and Installation Instructions, english, KNF 121581-121584 08/16
1. About this document
1.1. Using the Operating and Installation Instruc-
tions
The Operating and Installation Instructions are part of the pump.
Pass on the Operating and Installation Instructions to the next
owner.
Customer-specific project pumps (pump models which begin with
"PJ" or "PM") may differ from the Operating and Installation In-
structions.
For project pumps, also observe the agreed upon specifica-
tions.
1.2. Symbols and markings
Warning
WARNING
A danger warning is located here.
Possible consequences of a failure to observe the
warning are specified here. The signal word, e.g.
Warning, indicates the danger level.
Measures for avoiding the danger and its conse-
quences are specified here.
Danger levels
Signal word
Meaning
Consequences if not observed
DANGER
warns of immedi-
ate danger
Death or serious injuries
and/or serious damage are the
consequence.
WARNING
warns of possible
danger
Death or serious injuries
and/or serious damage are
possible.
CAUTION
warns of a possibly
dangerous situa-
tion
Minor injuries or damage are
possible.
Tab. 1
Other information and symbols
An activity to be carried out (a step) is specified here.
1. The first step of an activity to be carried out is specified here.
Additional, consecutively numbered steps follow.
This symbol refers to important information.
Project pumps

Swing Piston Pumps NPK 25 Use
Translation of original Operating and Installation Instructions, english, KNF 121581-121584 08/16 3
2. Use
2.1. Proper use
The pumps are designed for pumping air.
Owner's responsibility
Only install and operate the pumps under the operating parameters
and conditions described in Chapter 4, Technical data.
Before using a medium, check whether the medium can be trans-
ferred danger-free in the specific application case.
When using a medium other than air: Before using a medium,
check the compatibility of the materials of the pump head, swing
piston and piston seal with the medium.
2.2. Improper use
The pumps may not be operated in an explosive atmosphere.
The pumps may not be used to pump combustible or potentially
explosive media.
The pumps are not suitable for pumping vapors or liquids.
Operating parameters and
conditions
Requirements for
transferred medium

Safety Swing Piston Pumps NPK 25
4 Translation of original Operating and Installation Instructions, english, KNF 121581-121584 08/16
3. Safety
Note the safety precautions in sections 6. Installation and
connection, and 7. Operation.
The pumps are built according to the generally recognized rules of
technology and in accordance with the occupational safety and
accident prevention regulations. Nevertheless, dangers can result
during its use which lead to injuries to the user or others, or to
damage to the pump or other property.
Only use the pumps in proper technical condition and in accord-
ance with its intended use in a safety and danger-conscious man-
ner while observing the Operating and Installation Instructions.
Make sure that only trained and instructed personnel or specially
trained personnel work on the pump. This especially applies to
assembly, connection and servicing work.
Make sure that the personnel has read and understood the Operat-
ing and Installation Instructions, and in particular the "Safety"
chapter.
Observe the accident prevention and safety regulations when
performing any work on the pump and during operation.
When transferring dangerous media, observe the safety regula-
tions when handling these media.
Store all replacement parts in a protected manner and dispose of
them properly in accordance with the applicable environmental
protection regulations. Observe the respective national and inter-
national regulations. This especially applies to parts contaminated
with toxic substances.
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
commissioned until such time as it has been determined that the
machine in which the partly completed machinery is to be
assembled is in conformity with the provisions of the Machinery
Directive 2006/42/EC. The following 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.
(* only for pump type NPK 25 AC)
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 and hot
parts, if existing, has to be provided when mounting.
Personnel
Working in a safety-
conscious manner
Handling dangerous media
Environmental protection
EC Directives / Standards

Swing Piston Pumps NPK 25 Safety
Translation of original Operating and Installation Instructions, english, KNF 121581-121584 08/16 5
The pumps conform to the Directive 2011/65/EU (RoHS2).
The following harmonized standards have been used:
NPK 25 AC
NPK 25 DC
DIN EN 55014-1/2
DIN EN 55014-1/2
DIN EN 61000-3-2/3
DIN EN 60034-1
DIN EN 60335-1
DIN EN 50581
DIN EN 50581
Tab. 2
Only have repairs to the pump carried out by the KNF Customer
Service responsible.
Customer service and repairs

Technical data Swing Piston Pumps NPK 25
6 Translation of original Operating and Installation Instructions, english, KNF 121581-121584 08/16
4. Technical data
Pump materials
Assembly
Material
Head plate; cylinder
Aluminium
Valve plate
Stainless steel
Piston seal
PTFE compound
O-ring
FPM
Retainer plate
Aluminium
Tab. 3
Pneumatic values
NPK 25 AC
Parameter
Value
Max. permissible operating pressure [bar g]
5
Ultimate vacuum [mbar abs.]
180
Delivery rate at atm. pressure [l/min]*
30
Tab. 4 *Liters in standard state (1,013 mbar)
NPK 25 DC
Parameter
Value
Max. permissible operating pressure [bar g]
4
Ultimate vacuum [mbar abs.]
180
Delivery rate at atm. pressure [l/min]*
25
Tab. 5 *Liters in standard state (1,013 mbar)
Electrical data
Parameter
Value
Electrical data
See type plate
Protection class
IP 20
Tab. 6
The AC motors used are fitted as standard with a thermal-switch to
protect against overloading.
Other parameters
Parameter
Values
Permissible
ambient temperature
+ 5 °C to + 40 °C
Permissible media temperature
+ 5 °C to + 40 °C
Gas-tightness
The gas-tightness of the pump
is dependent on the medium
used.*
* If you have questions about this, please contact your KNF advisor.
Tab. 7

Swing Piston Pumps NPK 25 Design and function
Translation of original Operating and Installation Instructions, english, KNF 121581-121584 08/16 7
5. Design and function
Design
1Pneumatical outlet
2Pneumatical inlet
3Front fan cover
4Pump housing
5Base plate
6Motor
Fig. 1: Swing piston compressor and vacuum pump NPK 25 AC
Function
1Inlet valve
2Outlet valve
3Transfer chamber
4 Retainer plate
5Piston seal
6 Eccentric
7Connecting rod
8Compressor housing
Fig. 2: Function of swing piston pump
The pumps transfer, compress and evacuate air.
The swing piston, consisting of retainer plate (4) and piston seal
(5), is moved up and down by the eccentric (6) and the connecting
rod (7). In the downward stroke the swing piston aspirates the
medium to be transferred via the inlet valve (1). In the upward
stroke, the swing piston presses the medium out of the pump head
via the outlet valve (2). The swing piston is sealed off from the
compressor housing by a piston seal (5) and operates oil-free.

Installation and connection Swing Piston Pumps NPK 25
8 Translation of original Operating and Installation Instructions, english, KNF 121581-121584 08/16
6. Installation and connection
Only install and operate the pump under the operating parameters
and conditions described in Chapter 4, Technical data.
Observe the safety precautions (see Chapter 3).
6.1. Installation
Before installation, store the pump at the installation location to
bring it up to room temperature.
For the mounting dimensions see fig. 3 (NPK 25 AC) or fig. 4
(NPK 25 DC)
Fig. 3: Mounting dimensions NPK 25 AC
(All dimensions tolerances conform to DIN ISO 2768-1,
Tolerance Class V)
Fig. 4: Mounting dimensions NPK 25 DC
(All dimensions tolerances conform to DIN ISO 2768-1,
Tolerance Class V)
Mounting dimensions

Swing Piston Pumps NPK 25 Installation and connection
Translation of original Operating and Installation Instructions, english, KNF 121581-121584 08/16 9
For pumps with AC motors:
WARNING
Hazard of injuries during operation
Take protective measures against touching parts
connected to electrical power (electrical connec-
tion).
Install the pump so that the motor fan can intake sufficient
cooling air.
Make sure that the installation location is dry and the pump is
protected against rain, splash, hose and drip water.
Install the pump at the highest point in the system to prevent
condensate from collecting in the pump head.
Protect the pump from dust.
Protect the pump from vibrations and jolts.
6.2. Electrical connection
For pumps with AC motor:
DANGER
Extreme danger from electrical shock
Only have the pump connected by an authorized
specialist.
Only have the pump connected when the power
supply is disconnected.
For pumps with DC motor:
2. Only have the pump connected by an authorized specialist.
3. Only have the pump connected when the power supply is
disconnected.
In the electrical installation, arrangements (complying with EN
60335-1) must be made for disconnecting the pump motor
from the electrical supply.
For pumps with AC motors KNF recommends that a fuse is
installed in the motor supply circuit (overcurrent release).
For operating current see type plate or data sheet.
Connecting pump
1. Compare the supply data with the data on the motor-plate.
The voltage must not vary by more than + 10% and - 10%
from that shown on the type-plate.
2. NPK 25 AC
Connect the mains cables to the connections L1 and N of the
pump motor.
Protection against touching
Cooling air supply
Installation location

Installation and connection Swing Piston Pumps NPK 25
10 Translation of original Operating and Installation Instructions, english, KNF 121581-121584 08/16
NPK 25 DC
Connect the positive and negative pole.
With DC motors, note the proper polarity:
red motor cable: +
black motor cable: -
3. Connect the earth (ground) wire to the motor (not necessary
on dc motors up to 24 V).
EMC-compatible Installation (for NPK 25 DC)
The Tests:
- Magnetic field with energy-technical frequency
- Electromagnetic HF field, amplitude-modulated
- Electromagnetic HF field, pulse-modulated
- Discharging of static electricity
- High frequency, asymmetric
- Fast transients
were not carried out, cause the products do not contain electronic
modules, which can be affected by these tests.
The Surge-test can only be passed with additional means, or is not
mandatory, if: From EN61000-6-1 technical norm for EMC protec-
tion, part 1,10 test demands for EMC protection, table 3, EMC
protection, D.C.- power in- and outputs. Remark 3: (quotation) Not
to be used with input connections which are foreseen for a connec-
tion with a battery or a rechargeable battery which has to be re-
moved or disconnected from the device for the recharge.
Devices with a D.C. power input which are foreseen to be operated
with an A.C. / D.C. converter have to be tested at an A.C. power
input of an A.C. / D.C. converter fixed by the manufacturer. In case
the converter was not fixed they have to be tested at an A.C.
power input of a typical (usual) A.C. / D.C. converter.
The test is applicable for D C power inputs which are foreseen for
a permanent connection to cables which are longer than 10 m.

Swing Piston Pumps NPK 25 Installation and connection
Translation of original Operating and Installation Instructions, english, KNF 121581-121584 08/16 11
6.3. Pneumatic connection
Only connect components to the pump which are designed for
the pneumatic data of the pump (see Chapter 4, Technical da-
ta).
If the pump is used as a vacuum pump, safely discharge the
pump exhaust.
Connecting pump
A marking on the pump head shows the direction of flow.
4. Remove the protective plugs from the hose connection
threads.
5. The accessory silencer/filter (where applicable) is screwed
into the port thread.
If the pump is used as a vacuum pump, mount the silencer at
the pressure side if necessary. If the pump is used a compres-
sor, mount the filter at the suction side if necessary.
6. Connect the suction line and pressure line (threadsize G ¼``).
7. Lay the suction and pressure line at a downward angle to
prevent condensate from running into the pump.
Connected
components
Pump exhaust

Operation Swing Piston Pumps NPK 25
12 Translation of original Operating and Installation Instructions, english, KNF 121581-121584 08/16
7. Operation
Only operate the pumps under the operating parameters and
conditions described in Chapter 4, Technical data.
Make sure the pumps are used properly (see section 2.1).
Make sure the pumps are not used improperly (see section 2.2).
Observe the safety precautions (see Chapter 3).
WARNING
Hazard of the pump head bursting due to excessive
pressure increase
Do not exceed max. permissible operating
pressure (see Chapter 4, Technical data).
Only throttle or regulate the air quantity (the gas
quantity) in the suction line to prevent the maxi-
mum permissible operating pressure from being
exceeded.
If the air quantity (the gas quantity) in the pres-
sure line is throttled or regulated, make sure that
the maximum permissible operating pressure is
not exceeded.
Monitor pressure during operation.
If the pressure exceeds the maximum permissi-
ble operating pressure of the pump, immediately
switch off pump and eliminate fault (see Chapter
9. Troubleshooting).
Excessive pressure (with all of the related hazards) can be
prevented by placing a bypass line with a pressure-relief valve
between the pressure and suctions sides of the pump or by a
pressure-relief valve. For further information, contact our
technical adviser (see front page for telephone number).
With the pump at a standstill, open pressure and suction lines
to normal atmospheric pressure.
For pumps with thermal switch: When the operation of the pump is
interrupted by the thermal switch, the pump will restart automatical-
ly after cooling down.
Take all necessary care to prevent this leading to a dangerous
situation.
Change the silencer/filter (accessory) if it is dirty.
The pump may not start up against pressure or vacuum during
switch-on. This also applies in operation following a brief power
failure.
Make sure that normal atmospheric pressure is present in the
lines during switch-on.
Pump standstill
Thermal switch
Silencer/filter
Switching pump on

Swing Piston Pumps NPK 25 Servicing
Translation of original Operating and Installation Instructions, english, KNF 121581-121584 08/16 13
8. Servicing
8.1. Servicing schedule
Component
Servicing interval
Pump
- Regular inspection for external dam-
age or leaks
Piston seal and
valve plate
- Replace at the latest, when pump
output decreases
Tab. 8
8.2. Cleaning
Only use solvents for cleaning if the head materials cannot be
attacked (check the resistance of the material).
If compressed air is available, blow out the components.
8.3. Replacing piston seal and valve plate
Motor disconnected from mains and de-energized
Pump free of dangerous substances
Always replace the piston seal and valve plate together to
maintain the pump performance.
Spare part*
Position**
Quantity
Piston seal
(9)
1
Valve plate
(4)
1
Countersunk screw
(7)
1
O-ring D 32 x 2.0
(3), (5)
4
O-ring D 8.0 x 1.0
(8)
1
O-ring D 50 x 2.0
(12)
1
* According to spare parts list, chapter 10
** According to Fig. 5.
Tab. 9
Quantity
Tools/Material
1
Phillips screwdriver No. 1 (only for pump NPK 25 DC)
1
Phillips screwdriver No. 2
1
Screwdriver blade width 5.5 mm
1
Allen key 4 mm
1
Felt-tip pen
Tab. 10
Conditions
Information on procedure
Spare parts
Tools and material

Servicing Swing Piston Pumps NPK 25
14 Translation of original Operating and Installation Instructions, english, KNF 121581-121584 08/16
Prepatory step
1. Remove the front fan cover (Fig. 1/3, see page 6) of the pump
after loosening the four fixing screws.
Front fan is visible.
Removing pump head
1. Mark the position of head plate (2), intermediate plate (6) and
pump housing relatively to each other by a drawing line with a
felt-tip pen to ensure proper assembly.
2. Unscrew the four screws (1) and remove the head plate (2).
3. Remove the valve plate (4) from the intermediate plate (6).
4. Remove the intermediate plate (6).
5. Remove O-rings (5) from intermediate plate (6).
6. Remove O-rings (3) from head plate (2).
7. Check the intermediate plate (6) and head plate (2) for soiling
and damage. Clean the parts if necessary.
8. Contact KNF in case of roughness, scratches and corrosion.
Order and replace damaged parts.
9. Move the retainer plate (9) to the upper point by turning the
fan.
10. Pull cylinder (13) upwards.
11. Remove O-ring (12) from cylinder (13).
12. Hold on fan while loosening the countersunk screw (7) of
retainer plate (9).
13. Remove countersunk screw (7), O-Ring (8), retainer plate (9)
with piston seal (10).
14. Remove piston seal (10) from retainer plate (9).
15. Remove spacer(s) (11) from connecting rod (14).
16. Dispose of the old piston seal (10), valve plate (4), countersunk
screw (7) and O-rings properly.
Mounting pump head
1. Hold the connecting rod (14) from the front through the fan
opening, and replace the cylinder (13) on the pump housing.
2. Lay new O-ring (12) on cylinder (13).
3. Re-assemble the “piston-assembly”:
a. Lay the new piston seal (10) on the retainer plate (9).
For orientation of piston seal (10) see fig. 6.
b. Fit new O-ring (8) onto new countersunk screw (7).
c. Push the new countersunk screw (7) with new O-ring (8)
through the retainer plate (9).
4. Fit the same number of washer(s) (11) as previously used on
connecting rod (14).
Fig. 5: NPK 25 AC / NPK 25 DC:
Parts of pump head
Fig. 6: Orientation of piston seal
(10) in relation to retainer plate (9)

Swing Piston Pumps NPK 25 Servicing
Translation of original Operating and Installation Instructions, english, KNF 121581-121584 08/16 15
5. Slide “piston assembly” (consisting of retainer plate (9), piston
seal (10), and countersunk screw (7) with O-ring (8)) into the
cylinder (13) from the top and place on connecting rod (14).
The piston seal must not be distorted during assembly. It must
make contact with the cylinder all round its circumference
6. Fasten the “piston assembly” by tightening the countersunk
screw (7) (maximum tightening torque: 6.5 Nm).
7. Lay the two new O-rings (5) on intermediate plate (6).
8. Place the intermediate plate (6) on the pump housing in ac-
cordance with the felt-tip pen marking.
9. Place valve plate (4) on intermediate plate (6).
To align the valve plate, refer to fig. 5 and a groove in the
intermediate plate and valve plate: The two grooves must lie
on top of each other.
10. Insert the two new O-rings (3) into the underside of head plate
(2).
11. Place head plate (2) on intermediate plate (6).
Head plate and intermediate plate have a notch each which
must lay one upon the other.
12. Tighten the screws (1) at first lightly, then firmly by hand, in a
diagonal pattern (max. tightening torque 6.5 Nm).
Final step
1. Refit front fan cover.

Troubleshooting Swing Piston Pumps NPK 25
16 Translation of original Operating and Installation Instructions, english, KNF 121581-121584 08/16
9. Troubleshooting
NPK 25 AC:
DANGER
Extreme danger from electrical shock!
Disconnect the pump power supply before working
on the pump.
Make sure the pump is deenergized and secure.
NPK 25 DC:
Disconnect the pump power supply before working on the
pump.
Make sure the pump is deenergized and secure.
All pumps:
Check the pump (see Tab. 11 and 12).
Pump does not transfer
Cause
Fault remedy
Thermal switch has operated
following to over-heating.
Disconnect pump from mains.
Allow pump to cool.
Trace cause of over-heating and eliminate it.
Connections or lines blocked.
Check connections and lines.
Remove blockage.
External valve is closed or filter
is clogged.
Check external valves and filters.
Condensate has collected in
pump head.
Install pump at highest point in system.
Piston seal or valve plate is
worn.
Change piston seal and valve plate (see section 8.3).
Tab. 11
The pump does not achieve the output (flow, pressure or vacuum) specified in the Technical
data or the data sheet
Cause
Fault remedy
Condensate has collected in
pump head.
Install pump at highest point in system.
There is gauge pressure on
pressure side and at the same
time vacuum or a pressure
above atmospheric pressure on
suction side.
Change the pressure conditions.
Pneumatic lines or connection
parts have an insufficient cross
section.
Disconnect pump from system to determine output values.
Eliminate throttling (e.g. valve) if necessary.
Use lines or connection parts with larger cross section if
necessary.
Leaks occur on connections,
lines or pump head.
Eliminate leaks.
Connections or lines completely
or partially jammed.
Check connections and lines.
Remove the jamming parts and particles.

Swing Piston Pumps NPK 25 Troubleshooting
Translation of original Operating and Installation Instructions, english, KNF 121581-121584 08/16 17
The pump does not achieve the output (flow, pressure or vacuum) specified in the Technical
data or the data sheet
Cause
Fault remedy
Head parts are soiled.
Clean head components.
Piston seal or valve plate is
worn.
Change piston seal and valve plate (see section 8.3).
Tab. 12
Fault cannot be rectified
If you are unable to determine any of the specified causes, send
the pump to KNF Customer Service (see last page for the ad-
dress).
1. Flush the pump to free the pump head of dangerous gases.
For this purpose, flush the pump under atmospheric condi-
tions some minutes with air (if necessary for safety reasons:
with an inert gas).
2. Remove the pump.
3. Clean the pump (see Section 8.2)
4. Send the pump, together with completed Health and Safety
Clearance and Decontamination Form (Chapter 12), to KNF
stating the nature of the transferred medium.

Spare parts and accessories Swing Piston Pumps NPK 25
18 Translation of original Operating and Installation Instructions, english, KNF 121581-121584 08/16
10. Spare parts and accessories
Spare parts
Spare part
Position*
Order No.
Piston seal
(10)
112635
Valve plate
(4)
113984
Countersunk screw
(7)
110712
O-ring D 32 x 2.0
(3), (5)
116407
O-ring D 8.0 x 1.0
(8)
116408
O-ring D 50 x 2.0
(12)
006709
Tab. 13 *according to Fig. 5
Accessories
Accessory
Order No.
Silencer/filter
007007
Hose connector*
000362
Sealing for hose connector
001818
Tab. 14 * requires Sealing for hose connector Order No. 001818

Swing Piston Pumps NPK 25 Returns
Translation of original Operating and Installation Instructions, english, KNF 121581-121584 08/16 19
11. Returns
Pumps and systems used in laboratories and process-based
industries are exposed to a wide variety of conditions. This means
that the components contacting pumped media could become
contaminated 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
To ensure worker safety, work may not be started on pumps or
systems without a signed Health and safety clearance and decon-
tamination form.
For optimal processing of a return, a copy of this declaration
should be sent in advance via e-mail, regular mail, or fax to KNF
Customer Service (refer to final page for address). In order to avoid
endangering employees who open the shipment's packaging,
despite any residual hazards, the original version of the Health and
safety clearance and decontamination form must accompany the
delivery receipt on the outside of the packing.
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.
The customer must specify the device type(s) and serial number(s)
in the Health and safety clearance and decontamination form in
order to provide for the unambiguous assignment of the Declara-
tion to the device that is sent to KNF.
In addition to the customer's declaration of physiological safety,
information 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.

Health and safety clearance and decontamination form Swing Piston Pumps NPK 25
KNF worldwide
Find your local KNF partner on www.knf.com
12. Health and safety clearance and decon-
tamination form