Assembly and Operating Instructions for Netter Pneumatic Impactors
Contents
1. Check total number of impacts Air supply lines Silencer Check impacts Mist lubricator Filter of the mainte nance unit Filter empfohlen Screw connections should be checked and if necessary tightened and secured with Loctite after one hour of operation after first commissioning and then at regular intervals After a maximum of 500 000 impacts a comprehensive service should be carried out during which all seals and guide rings should be replaced Check for kinks and ensure that the lines are free from obstructions If necessary clean the hoses and remove kinks Clean and check function Check function Make sure that mist lubricator works correctly contents decreasing Number of drops h Refill oil Empty filter if necessary clean wash out filter insert or replace filter insert The maintenance intervals largely depend on the operating period and the cleanness of the drive medium Especially in units driven by oil free and or dried compressed air increased friction can create deposits which will slow down the function If this is noticed performance loss or even standstill the impactors should be cleaned and the sealing and guide rings replaced if necessary The maintenance intervals are reduced Cleaning the impactor When cleaning the impactor it is necessary to remove and clean the piston In case of wear the guide rings and piston seals must be replaced A special tool is2. PKL 2100 oy PKL 5000 ans PKL 2100 and PKL 5000 must always be installed with impact plate and damper Impact plate Damper plate late p p ot Use lock nuts or a locking fluid e g Loctite 270 in order to prevent loosening Also secure the compressed air supply lines with a suitable retention agent Use the tightening torques shown in the table below Higher tightening torques can lead to the fracturing of screws or tearing of threads Incorrect attachment of screws can lead to detachment of the device due to vibration This can result in personal injury and damage to material CAUTION Recommended average tightening torques for screws property class 8 8 on PKL housings screws as delivered with no additional lubrication Type Tightening torque PKL 190 PKL 450 PKL 740 PKL 2100 PKL 5000 When using fastening sets NBS series with screw or elastomer springs the tightening torques are lower CAUTION Please observe the information and instructions supplied with these accessories PKL 190 and PKL 450 with NBS The PKL 450 with ST kit is first attached to the dampening set NBS 450 and then the lower ST screws are mounted Example PKL 450 Dampening set NBS 450 Installation PKL A cock valve 1 to shut off the main line and a The maintenance unit should consist of fil maintenance unit 2 are recommended for all ter regulator and mist lubricator see installations chapter 3 Technical Data Dri
3. necessary available upon request to insert the piston Alternatively maintenance repair and comprehensive servicing can be carried out by NetterVibration 20 9 Troubleshooting Fault Possible causes__ Troubleshooting Mounting surface not Pressure loss viaj Ensure mounting surface ae plane O ring with flatness error 0 1 mm Malfunction of valve Check impactor Check 3 2 way valve and and control without valve and control replace if control necessary Air supply Check pressure Adjust operating pressure Check valve switching Replace valve if necessary No function Seals are worn Check seals of Replace seals on the with leakage knocking and control knocking and control from top pistons PKL 190 pistons General wear Housing membrane Replace affected parts and and control piston seals worn No function PKL not mounted Check fastening Tighten fastening screws or with leakage correctly screws replace if necessary on the mount ing surface Mounting surface not Check mounting Ensure mounting surface i T surface with flatness error 0 1 mm Check O ring Insert O ring into the groove and replace it if damaged No function Operating pressure Check unit type Increase pressure with ST kit too low Check pressure Weak impact Air supply Check pressure Adjust pressure Control valve soiled Check control valve Clean control valve or replace if necessary Silencer
4. 0 G1 8 NW6x1 0152 3765 4 Design and Functioning The pneumatic interval impactor is a pneumatic hammer Compressed air P flows beneath the piston C and pushes it against one or two springs B Upon exhaust the air chamber below the piston is emptied all at once The piston C hammer is shot against an elastomer EE kit or against an impact plate E by the springs and the plate transfers the blow F lf no Elastomer is used the piston hits directly against the mounting surface In the standard versions the impact plate is always made of steel and can be replaced by an Elastomer impact plate The air is evacuated via the silencer A The unit is attached via flange D by four fastening screws PKL 190 and PKL 450 2 fastening screws Pneumatic impactors only work after assembly since the piston chamber is then sealed by an o ring installed in the contact Surface ST kit The ST kit permits a continuous impact se quence with permanent compressed air supply Special feature of PKL 740 without illustration A 3 2 way valve and a quick air exhaust valve are integrated in the valve head of the PKL 740 The control valve existing on customer s site can therefore be mounted at any distance from the PKL 740 The pilot air supply must be connected laterally A silencer is mounted on the exhaust outlet for the ventilation EE kit The EE kit reduces the sound level and creates a r
5. The admissible ambient temperatures must not be exceeded or fallen short of during operation Higher operating pressures and temperatures are only possible following consultation and written permission from Netter GmbH application engineers Type designation The type designation of PKL impactors has the suffix 3 4 5 or 6 These numbers are derived from the optimum operating pressure i e the PKL 740 4 works most effectively at a pressure of 4 bar Operating time The technical performance data will change in the course of the operating time wear Dimensions PKL 190 PKL 450 a cS gp p z J J a Me a i r 1s Noise level Preferably the PKL should be installed with the EE kit This reduces the impulse rubber hammer effect With this kit the noise level is around 75 dB A individual sound event Depending on the impact sequence the continuous noise level is below this value The sound emitted by the PKL can be dampened by a cover upon request This only makes sense if the impacted sheet metal is also dampened e g by heat insulation material PKL 740 PKL 2100 PKL 5000 D TPP e erl mm d ry CEY T PKL 190 it rare NWext 900 1635 PKL 450 735 126 14 130 G1 eNW6x1 900 1920 PKL 740 90 140 15 130 50 G1 8NW6x1 100 0 2985 PKL 2100 0120 0180 17 13 0 G1 8 amp NW6x1 152 301 5 PKL 5000 0114 3 0180 22 17
6. connects the control port with the piston chamber The impactor strikes as long as air is applied to P See Assembly Instructions for ST kit Circuit diagrams see chapter 6 Installation Example PKL 450 ST kit for PKL 2100 and PKL 5000 The ST control connects the control port with the piston chamber and is integrated in the PKL ST kit for PKL 5000 In this case a control valve has to be mounted onto the PKL The control valve is internally connected to the piston chamber The impactor then continues to strike as long as compressed air is applied See Assembly Instructions for ST kit The impact sequence can be set by means of a throttle optionally Circuit diagrams see chapter 6 Installation EE kit for PKL 190 PKL 450 and PKL 740 A spacer plate with a replaceable elastomer and 0 ring is installed between impactor and mounting surface See Assembly Instructions for EE kit Example PKL 190 PKL5000 1 e g EE kit for PKL 190 EE kit for PKL 2100 and PKL 5000 The piston hits against an impact plate The air channel is integrated in the housing The exhaust air escapes into the atmosphere via the silencer A 3 2 way air valve is required if the control valve at the customer s site is mounted at a distance of more than 15 m from the PKL lf the impactor is fitted with the EE kit the steel impact plate with damper ring and O ring is replaced by an elastomer impact plate with O ring
7. severe Pneumatic impactors are not mechanically closed on the impact side A The impact piston and or impact plate are loosely mounted Possible consequences of non observance JS X Falling parts can cause injury or material damage Caio Avoiding the danger Ensure that the impact piston and or impact plate remain in the housing during installation and disassembly DANGER A CAUTION Source of danger Impactors parts of the construction and air connectors may become loose due to vibration Possible consequences of non observance Falling parts can cause material damage or injury Avoiding the danger Screw retention devices and or Loctite or similar are to be used Screwed connections and air connectors should be checked after 1 hour of operation and then at regular intervals generally once per month and tightened if necessary Netter fastening sets NBS are recommended for the attachment of impactors Pneumamatic impactors PKL 450 should be installed with a dampening set PKL 2100 and PKL 5000 must be mounted with a damper plate In critical installation situations it is required to secure the vibrator with a clamp and steel rope Source of danger In the vicinity of the impactor or structures connected to the impactor the noise level can exceed 85 dB A Possible consequences of non observance Human hearing can be permanently damaged by the high noise level Avoiding the danger When
8. soiled Check silencer Clean silencer Wear leakage Replace the seals 10 Spare Parts When ordering parts please supply the following details 1 Required quantity 2 Description and position of the spare part 3 Type of unit 21 11 Accessories The following accessories are available for the pneumatic impactor PKL upon request NBS 190 for PKL 190 NBS 450 for PKL 450 NBS 1 2 and 5 for PKL 740 Fastening sets NBS NBS 2100 for PKL 2100 NBS 5000 for PKL 5000 screws springs and matching lock washers for secure fastening When using this type of control the pauses between the ST kit individual impactor sequences must be long enough see Chapter 6 ae For compressed air supply working air pilot air in various Hose material and fittings alities and dimensions Filter regulator with pressure gauge mist lubricator For round and rectangular containers also for use on insulated Weld on consoles g containers funnels etc Vacuum fixing devices l l E For quick rel ion on containers etc quick clampina devices or quick relocation on containe Hoods covers EE kit Clamp with steel rope and snap hooks Netter start control For long supply lines gt 15m Seat Flanges with different dimensions available at extra cost Special versions high temperature versions and further information on request 22 12 Disposal The parts are to be correctly disposed of depending on the material Material speci
9. 5 even if it is mounted at a greater distance possible up to 50m lf a Netter electronic timer AP 4 is used the PKL strikes several times during the duty time Installation with coupling to other functions lf the PKL 740 is fitted with an ST kit it can be coupled to other functions without having to use a control or pulse generator The adjoining illustration shows the coupling to an opening cylinder 8 on a weighing container The impactor is not activated Once the flap is opened the impactor will strike at the frequency set by the throttle as long as the flap remains open Recommended cross sections for valves and hoses PKL 190 PKL 450 PKL 740 PKL 2100 and PKL 5000 Control lines control valves NW 6 x 1 Main air supply NW 6 x 1 Use NW 6 for connection of the control valve to PKL and do not exceed a length of 15 m For simultaneous activation of several PKLs greater cross sections have to IMPORTANT be used for the main air supply line For the activation of several PKL the total length of the compressed air supply lines must not exceed 50 m Check list for installation 1 Consider expected operating temperature 2 Install main cock and maintenance unit filter regulator as required valve and supply line 3 Mount weld on console if necessary 4 Install with fastening set NBS 5 Install PKL 2100 and PKL 5000 with damper plate 6 Secure fastening screws with glue e g Loctite 7 Gl
10. CE NetterVibration N V Assembly and Operating Instructions Feb 2013 for Netter Pneumatic Impactors A ax een Original Operating Instructions 9 These operating instructions apply to PKL 190 Netter GmbH www NetterVibration com Germany Fritz Ullmann StraBe 9 55252 Mainz Kastel Tel 49 6134 2901 0 Fax 49 6134 2901 33 info NetterVibration de PKL 450 PKL 740 PKL 2100 PKL 5000 Switzerland Poland Enlenweg 4 Al W Korfantego 195 17 4310 Rheinfelden 40 153 Katowice Tel 41 61 8316200 Tel 48 32 2050947 Fax 41 61 8311291 Fax 48 32 2051572 info NetterVibration ch info NetterVibration pl Contents 1 GENERAL NOTES 2 SAFETY 3 TECHNICAL DATA 4 DESIGN AND FUNCTIONING 5 TRANSPORT AND STORAGE 6 INSTALLATION 7 START UP OPERATION 8 MAINTENANCE REPAIR 9 TROUBLESHOOTING 10 SPARE PARTS 11 ACCESSORIES 12 DISPOSAL 13 ENCLOSURES Scope of delivery The PKL are delivered with the following components as standard e Pneumatic impactor PKL e Operating instructions e Packaging For changes to the scope of delivery please refer to the delivery note 10 11 19 20 21 21 22 23 24 Check the packaging for possible signs of transport damage In the event of damage to the packaging check that the contents are complete and undamaged If there is any damage inform the shipping agent Com pare the scope of the delivery with the deliv ery note 1 General Notes Information on t
11. PKL 450 and PKL 740 are open on the impact dl side Ensure that the impact piston remains in the housing during installation CAUTION Impactors of the series PKL 2100 and PKL 5000 must always be installed CAUTION with impact plate and damper plate included in the scope of delivery PKL impactors are screwed to level reinforcement sections or weld on consoles 0 3mm flatness Suitable weld on consoles see illustration on the right are available from NetterVibration see Accessories Weld on plates must not be welded directly onto the panels of the construction since they are too stiff Use an intermediate layer of 1 5 times the sheet thickness example A Particularly in the type of attachment shown in A the screws may break and are then difficult to replace in contrast to example B The fastening sets NBS serve to securely and permanently fasten the PKL impactors NetterVibration supplies these fastening sets NBS screw springs and matching washers on request ST kit for PKL 740 The ST kit connects the control port with the piston chamber The impactor continues to strike as long as compressed air is applied In this case only one air supply line is required see Assembly Instructions for ST kit Attention For installations with automatic control ST the silencer must be screwed on to the air supply ST kit for PKL 190 and PKL 450 In this case a 3 2 way valve with air supply to P is required The ST kit
12. ck off stubborn residues from walls to evacuate residues from weighing containers and to prevent bridging and rat holing as long as the material remains capable of flowing Any other use is considered improper use There are no built in safety devices Qualification of the personnel Assembly commissioning maintenance and repair of the impactors must be performed only by authorized qualified per sonnel Any handling of the pneumatic impactors lies within the responsibility of the operator Accessories which ensure the correct operation and safety must provide a protection type required for the specific use Netter GmbH does not assume liability for damage or injury resulting from technical modifications to the product or failure to observe the CAUTION _ Nstructions and warnings in this operating manual Source of danger Faulty hose connections Possible consequences of non observance A pressurized hose coming loose can cause severe injury CAUTION Avoiding the danger The hose lines must be securely connected This must be checked at regular intervals and the screw connections have to be retightened if necessary Source of danger PKL impactors work with compressed air injury CAUTION Avoiding the danger Ensure that the compressed air is shut off from the supply lines when working on the PKL Source of danger Possible consequences of non observance A pressurized hose coming loose can cause
13. dditional 3 2 way valves 9 are used If several PKLs are operated the overall length of the air supply line must not exceed 50 m Example PKL 450 Installation with ST kit With an ST kit the PKL continues to strike as long as pressure is applied The PKL can then achieve an impact frequency of approx one impact second This maximum impact sequence must be reduced to the max permissible impact sequence e g using a throttle valve 6 installed in the air supply line With an ST kit a PKL can be operated with a 2 3 or 4 way valve 3 even if it is located at a greater distance up to 50 m The length of the connecting lines from valve to PKL must not exceed 1 m otherwise the control piston or the membrane in the unit will move too slowly and not reach the sealing final position Examples PKL 450 and PKL 2100 at E E Paso E O PKL 2100 TY an META i j S A 4 HH Installation with coupling to other functions lf the PKL 740 is fitted with an ST kit it can be coupled to another function without having to use a control or pulse generator The adjoining illustration shows the coupling to an opening cylinder 8 on a weighing container The impactor is not activated Once the flap is opened the impactor will strike at the frequency set by the throttle as long as the flap remains open Example PKL 2100 Installations for PKL 740 Standard installation The PKL 740 is t
14. fications i PKL190 PKL 450 PKL 740 PKL 2100 PKL 5000 Reducer ia aa ST tube ST plate ST connecting angle impact plate outer tube inner tube piston piston impact piston impact plate springs springs springs top cover flange ST tube impact piston springs piston springs inner tube i outer tube i ee ae Saat housing reducer top cover flange ST Ring ST plate seals seals PTFE PU ea cover poe dampening rings dampening rings VITON NBR g Stop seals i dampening plates dampening plates seals membranes impact plate EE impact plate EE Valves Brass nickel plated Plastic All units can be disposed of through Netter GmbH The applicable disposal prices are available upon request 23 13 Enclosures Enclosure s co Additional information available upon Declaration of incorporation request IMPORTANT Leaflet No 27 PKL and others 24
15. he only PKL with integrated 3 2 way pneumatic valve in the valve head Upon switching of the valve the piston chamber is ventilated and exhausted and the impactor is striking The impact sequence can be determined by a Netter electronic timer AP 4 Electric and pneumatic controls are available on request The main air supply is constantly applied to the valve head The control line from the activation valve existing on customer s site 3 and the impactor can be very long e g 50 m In case of long supply and control lines the charge time of the impactor can take several seconds If the compressed air lines are long e g 50 m a pause and duty time of at least 5 seconds should be set on the electronic timer AP 4 If shorter lines are used these times can be reduced accordingly e g to 2 3 seconds PKL 2100 A DE KL 740 BA Installation of several PKL 740 Parallel operation of several PKL 740 is possible with just one control and one valve In this case the overall length of the air Supply line must not exceed 50 m Installation with ST kit With an ST kit 7 the PKL continues to strike as long as pressure is applied The PKL can then achieve an impact frequency of several impacts second This maximum impact sequence must be reduced to the max permissible impact sequence e g using a throttle valve 6 installed in the air supply line A PKL with ST control 7 can be activated using a 2 3 or 4 way valve
16. he operating instructions Use and storage of the operating instructions Before use of the pneumatic impactors of the series PKL read this operating manual carefully It is the basis for any action taken with regard to the PKL and may be used for training purposes The operating manual should subsequently be stored near the PKL Target group The target group of these operating instructions is qualified technical personnel from the mechanical engineering sector who have a basic knowledge of pneumatics and mechanics Installation commissioning maintenance fault elimination and disassembly of the PKL must only be performed by persons who have been instructed in the proper handling of the units Persons who have not been instructed accordingly must not carry out any works on the PKL Copyright This documentation is subject to copyright All rights e g for translation photo mechanical reproduction printing or reproduction e g data processing data carriers and data networks of this operating manual or parts thereof are Strictly reserved to NetterVibration Limitation of liability All technical information data and instructions on installation operation and maintenance in these operating instructions are based on the latest information available at the time of printing and take into account our past experience to the best of our knowledge No claims can be derived from the information illustrations and description
17. s in these operating instructions The manufacturer does not assume liability for damages resulting from e failure to observe the instructions improper use unauthorized repairs technical modifications use of inadmissible spare parts operating Translations are made to the best knowledge MNetterVibration does not assume liability for translation errors even if the translation was made by us or on our behalf Only the original German version is binding The following instruction and warning symbols are used in these operating instructions referring to a possible risk which if not avoided can result in death or serious injury referring to a possible risk which if not avoided can CAUTION result in serious injury and or equipment damage CAUTION referring to a possible risk which if not avoided can LOOSE PARTS result in serious injury or equipment damage IMPORTANT note with especially useful information and tips ENVIRONMENTALLY FRIENDLY DISPOSAL refers to the obligation of an environmentally friendly disposal Information on the PKLs Netter pneumatic impactors series PKL Special features comply with the EC machine directive e high impact force 2006 42 EC e low air consumption e reduced noise level due to elastomer In particular standard DIN EN ISO 12100 insert has been observed 2 Safety Designated use Impactors are intended for assembly into machinery where they are used to kno
18. tle cut off valve etc will not reduce the impact strength but will delay the charge time without ST control The impact frequency must be regulated using an external control e g with a 3 2 way valve and a Netter electronic timer AP Check list for start up 1 Check hose connections before opening the compressed air supply 2 If required set the desired impact force on the pressure regulator does not apply if ST kit is installed 3 If the ST kit is installed the frequency can be regulated using a throttle Do not set faster than necessary service life noise pollution 4 Adjust mist lubricator if existing 5 After 1 hour of operation the compressed air lines attachment and fastening screws should be checked and tightened if necessary After this the attachment and fastening screws and compressed air lines should be checked at regular intervals generally once per month and tightened if necessary CAUTION 8 Maintenance Repair IMPORTANT Before starting inspection or service work shut off the compressed air supply and CAUTION Protect it against unintentional activation The drive medium must be clean filter lt 5 um class 3 Unfiltered compressed air leads to high wear blocked silencers or complete break down of the impactor The maintenance intervals will be shorter Maintenance schedule Maintenance must be performed on a monthly basis DANGER IMPORTANT Screw connections
19. ubber hammer effect 5 Transport and Storage Check the packaging for possible signs of transport damage In the event of damage to the packaging check that the contents are complete and IMPORTANT Undamaged If there is any damage inform the shipping agent Compare the scope of delivery with the delivery note The units are packed ready to install The type label is attached to the impactor Accessories and add on parts are delivered unmounted unless otherwise agreed Special transport conditions are Stipulated The units should be stored in a clean dry environment not PKL impactors must be oiled before going back into storage pour machine oil into air inlet port and activate briefly Packaging The packaging protects the unit from transport damages The material of the packaging has been selected based on environmentally and _ disposal friendly aspects and can therefore be recycled PKL 190 PKL 450 and PKL 740 must be screwed or clamped to a plate before operation The impact plate must be inserted Use ear protections The storage temperature should be between 40 and 60 C This does not apply to the operating temperature reduces raw the waste Recycling material volume the packaging consumption and 6 Installation Ensure that the compressed air supply is shut off during installation or when working on the CAUTION mpactor and air supply lines Pneumatic impactors PKL 190
20. ue in air supply lines 8 Observe information on hose length and nominal width 9 Secure the unit against falling down 7 Start up Operation Lubricated compressed recommended for PKL impactors Sra Fill mist lubricator with acid and resin free I pneumatic oil ISO viscosity IMPORTANT according to DIN 51519 VG 5 to VG 15 class Recommendation Kluber AIRPRESS 15 for temperatures up to 60 C When selecting the lubricator bear in mind that the air consumption of the PKL is very low The selection of the lubricator is dependent on the number of impactors to be operated at the same time ATTENTION Adjust the number of drops with the unit running Units with 1 8 and 1 4 connectors are recommended Larger units may not respond Set to the lowest number of drops Only after the mist lubricator has been adjusted and is functioning correctly the device is ready for o operation Impact frequency Max 10 impacts in succession at an impact frequency of 15 impacts min and 180 impacts h CAUTION This impact sequence must not be exceeded Regulation of Impact Frequency PKL must be used for clocked operation only with ST control In a PKL with ST control the impact frequency can be regulated by means of the throttle Regulation of Impact Strength The impact strength can be reduced by lowering the pressure exception ST kit Throttling the air supply via a throt
21. ve medium ees IMPORTAN Connect the hoses of the PKL as shown on the pneumatic circuit diagrams T Installations for PKL 190 PKL 450 PKL 2100 and PKL 5000 Standard installation A 3 2 way valve 3 must be used for the control Upon switching of the valve the piston chamber is ventilated and exhausted and the impactor is striking The impact sequence can be determined by a Netter electronic timer AP 4 Electric Or pneumatic controls are available on request The 3 2 way valve 3 can be installed at greater distances up to 15 m from the impactor Examples PKL 450 and PKL 2100 Installation with long supply line If the supply line A exceeds 15 m an additional 3 2 way valve 9 and a throttle 6 must be installed Line B must have a minimum length of 1 m and during commissioning the throttle 6 must be adjusted so as to switch the 3 2 way valve 9 with time delay For this purpose the Netter start control can be installed available on request which includes all necessary components Example PKL 190 nstallation of several PKLs lt is possible to operate several impactors in parallel with just one control and one valve The length of the connecting lines from valve to the PKL must not exceed 1 m otherwise the control piston or membrane in the unit will move too slowly and not reach the sealing final position The 3 2 way valve 3 can be installed at greater distances from the impactor if a
22. working in the noise area ear defenders are required if the sound level exceeds 85 dB A Preferably the PKL should be installed with the EE kit 3 Technical Data Type Weight of Force of Optimum Air consumption Overall Suitable for piston impact operating impact weight wall pressure at optimum pressure thickness of kg g kg PKL 190 4 0 60 Normal liter PKL 5000 4 4 96 6 60 The impact force corresponds to the impact of the indicated weight falling from a height of 1m Admissible operating conditions Drive medium Clean Filter lt 5 um quality class 3 according to DIN ISO 8573 1 lubricated compressed air or lubricated nitrogen Lubrication Fill mist lubricator with acid and resin free pneumatic oil ISO viscosity class according to DIN 51519 VG 5 to VG 15 Recommendation Kluber AIRPRESS 15 for temperatures up to 60 C Operation in a dusty environment is possible In consultation with NetterVibration the PKL can also be operated without lubrication Operating pressure Operating pressures between 2 5 bar and 7 0 bar are possible The actual air pressure set on the regulator must not exceed the optimum pressure by more than 1 bar maximum pressure Frequency of impacts A maximum of 10 impacts in a row at an impact frequency of 15 impacts min and 180 impacts h This impact sequence must not be exceeded Ambient temperature 20 C to 60 C HT version 20 C to160 C
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