Assembly and Operating Instructions Netter Vacuum-Fixing
Contents
1. NetterVibration N V Assembly and Operating Instructions Aug 2013 Netter Vacuum Fixing Devices BA Nr 1386E Page 1 24 These operating instructions apply for VAC 8 VAC 13 VAC 10 VAC 15 VAC 11 VAC 20 VAC 12 VAC 30 VAC 40 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 Switzerland Erlenweg 4 4310 Rheintelden Tel 41 61 8316200 Fax 41 61 8311291 info NetterVibration ch Poland Al W Korfantego 195 17 40 153 Katowice Tel 48 32 2050947 Fax 48 32 2051572 info NetterVibration pl Table of Contents 1 GENERAL NOTES 3 2 SAFETY 5 3 TECHNICAL DATA 7 4 DESIGN AND FUNCTIONING 12 5 TRANSPORT AND STORAGE 13 6 INSTALLATION 14 7 START UP OPERATION 21 8 SERVICE MAINTENANCE 22 9 TROUBLESHOOTING 23 10 SPARE PARTS 24 11 ACCESSORIES 24 12 WASTE DISPOSAL 24 13 ENCLOSURES 24 Scope of delivery The VAC are delivered with the following Check the packaging for possible signs of components as standard transport damage In the event of damage e Vacuum fixing device VAC to the packaging check that the contents e Operating instructions are complete and undamaged If there is e Packaging any damage inform the shipping agent e From series VAC 11 safety rope Compare the scope of the delivery with the delivery note For changes to the scope of delivery please refer to the delivery note 1 Genera2. The noise level was measured at a distance of 1 m without vibrator The noise level of vibrators is in most cases higher Admissible operating conditions Drive medium Clean Filter lt 5 um quality class 3 according to DIN ISO 8573 1 com pressed air or nitrogen Unfiltered air will cause damage to the mounted vibrators Lubrication VAC fixing devices do not require lubrication For the mounted vibrator lubricated compressed air may be specified Please IMPORTANT refer to the corresponding operating instructions for the vibrator Operating pressure 4 bar to 6 bar Operating pressures must not be exceeded or fall short of Ambient temperature 10 C to 60 C The admissible ambient temperatures must not be exceeded or fallen short of during operation Higher operating pressures and temperatures are only permitted after consultation and written confirmation by application engineers of NetterVibration Dimensions VAC 8 VAC 10 VAC 11 VAC 12 All dimensions in mm measurement X depending on vibrator ee ee ee E 68 100 100 VAC 15 VAC 20 p Ea pana I eaaa l L Mnl l mm Wi ie F 150 200 All dimensions in mm measurement X depending on vibrator Type A B D E VAC 15 VAC 20 VAC 30 A Type JAB CDE VAC 30 All dimensions in mm measurement X depending on vibrator VAC 40 A A E 6 P VAC 40 All dimensions in mm E X depending o
3. of vibrators to smooth and to a limited extent also to rough and curved surfaces They are used in combination with vibra tors for the emptying of transport contain ers or drums for the cleaning of pipes etc Vacuum fixing devices are used where conventional fastening methods for vibra tors fail frequent relocation of vibrators is required and welding or bolting is not pos sible Any other use is considered improper use There are no built in safety devices Qualification of the personnel Assembly start up maintenance and repair of the impactors must be performed only by authorized qualified personnel Any handling of the pneumatic impactors lies within the responsibility of the opera tor Accessories which ensure the correct operation and safety must provide a protection type required for the specific use NetterVibration does not assume liability for damage or injury resulting 1N from technical modifications to the product or failure to observe the CAUTION instructions and warnings in this operating manual Not every pneumatic vibrator is suitable to the vacuum fixing device Applicable vibrators are listed in chapter 6 Mounting of vibrator and hose set CAUTION When choosing a different vibrator a preceding consultation is required Source of danger In case of an unexpected pressure drop the vacuum fixing devices may come loose Possible consequences of non observance A fixing device dropping down
4. tapped blind holes must be drilled rubber lf a compressed air operated piston vibrator of series NTS or NTK is to be mounted we recommend the use of an adapter plate iem adapter plate SEN NS rubber Otherwise one hole must be drilled into the suction cup and the tapped hole sealed with a sealing agent e g Loctite For the thread X refer to the operating instructions for the respective vibrator rubber lt p When drilling blind holes make sure not to drill through the suction cup rubber ww However if this should happen you must seal the tapped holes with a sealing com IMPORTANT POUNG e g Loctite as other no vacuum can be generated VAC 13 VAC 15 VAC 20 VAC 30 and VAC 40 Installation of the Vibrator In order to mount the vibrator to a VAC 13 3 Drill through holes diameter depending VAC 15 or VAC 20 socket head cap on type of vibrator see operating in screws acc to DIN 7991 are required The structions for vibrator assembly can be performed as follows Countersink bores from bottom side of 1 Unscrew the suction cups base plate side of suction cup acc to 2 Determine and mark the necessary bore DIN 74 Bf holes commonly used bore pitches 4 Fasten the vibrator using the specified have already been marked with a centre socket head cap screws For this pur punch see template VAC 15 and VAC pose use common screw retentions 20 5 Assemble the suction cups in the c
5. HF 250 NF 350 HF 350 NF 50 oa 108 18AL 25 75 01 50 01 70 02 cite 57 55 108 70 02 54 02 50 04 32 48 126 S eee A 50 08 50 10 a Depending on application please consult NetterVibration Adapter plate required please add to your order Not every pneumatic vibrator is suitable to the vacuum fixing device With drill pat terns different to the ones for the above listed units the internal pilot bores may be damaged The above mentioned combinations fixing device vibrator have been tested and can be used without any limitations When choosing a different vibrator a preceding consultation is required A Use screw retentions and nuts to fasten the vibrator Use a liquid screw retention agent e g Loctite against loosening DANGER Use tightening torques according to the following table Higher tightening torques may cause fracture of screws or tearing of threads In adequate screw connections may cause loosening of units by vibration This can cause damage to persons and material 14 Recommended mean tightening torques for screws of quality 8 8 screws as supplied without additional lubrication Tightening torque Nm 80 190 380 Vibrators must be cautiously and properly fastened The fastening screws for the IMPORTANT Vibrator must be retightened or checked after 1 operating hour VAC 8 VAC 10 VAC 11 and VAC 12 Installation of the Vibrator In order to mount vibrators NCT two
6. ased on environmentally and disposal friendly aspects and can therefore be recycled Protect the vacuum fixing devices from ex cessive exposure to UV radiation The vacuum fixing devices should be stored in boxes in a dry and clean envi ronment When restocking all openings must be closed The storage temperature should be between 20 and 80 C This does not apply to the operating temperature reduces raw the waste Recycling material volume the packaging consumption and 6 Installation Make sure the compressed air supply is switched off during installation or any other work on vacuum fixing devices vibrator or air CAUTION supply lines Complete vacuum fixing devices with hose lf ordered separately hose set and vibrator set and vibrator are directly ready for oper must first be assembled ation after connection to compressed air The following vibrators can be mounted to the vacuum fixing devices ype Suitable vibrators NCB NCR NCT NTK NTS NTP PKL VAC8 HG10N gt SAL 15X 120 HF 120 NF AC8 HG 108 2 146 18AL 180 HE 180 NF AC10 HG 10N 15X 180 HE 180 NF AC104HG 105 S S S4 deat 250 HF 250 NF 25 130 AC11 HG 10 N 180 HF 180 NF 190 AC114HG 105 gt 10 310 18AL 250 HF 250 NF 450 AC12 HG 15 N 350 HF 350 NF 450 AC12 HG 15 S 0 20 22 EEN An 100 01 75 01 50 01 AC13 HG 15 N 1740 2100 te 20 22 15 29 aa 75 01 50 01 ss 10 20 22 15 29 250
7. can cause bodily injury and or damage to property Avoiding the danger DANGER lhe vacuum fixing devices VAC 8 and VAC 10 are by customer secured against drop down From series VAC 11 the vacuum fixing devices are fitted with an adjustable safety rope This rope must be pre tensioned as short as possible using a bulldog grip Should a holder come loose it should never drop into a slack rope DANGER DANGER DANGER Source of danger Faulty hose connections Possible consequences of non observance A pressurized hose coming loose can cause se vere injury 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 nec essary Source of danger Vibrators bolted to vacuum fixing devices may come loose by the effect of vibration Possible consequences of non observance Falling parts can cause damage to persons and material Avoiding the danger Screw retention components and or Loctite or similar must be used Screw connections must be checked and if necessary retightened after 1 hour of operation and then at regular intervals normally every month Source of danger With parts of smaller cross section there is a risk that a vacuum fixing device may come loose Possible consequences of non observance A fixing device dropping down can cause bodily injury and or damage to property Avoiding the dang
8. consumption can be reduced by approx 30 in comparison to the standard version by means of a restrictor This compressed air reduction makes sense because the holding function does not re R ckschlagventil quire the totally available compressed air The total pied ly available compressed air is only needed for op eration of the vibrator Hose set HG with DRV Both versions of the hose sets N and S are available with throttle control valve DRV and recommended by NetterVibration S prv Means of this valve the pressure which is ap VAC plied to the vibrator may be adjusted Thus there is the possibility of the speed of the vibrator and Jibei the impact frequency of the vibrator to adjust Se VAC Vibrator 5 Transport and Storage The vacuum fixing devices are packed ready for assembly The type designation is stamped on the base plate VAC 8 VAC 10 VAC 11 VAC 12 and VAC 13 or engraved VAC 15 VAC 20 VAC 30 and VAC 40 When ordering a vacuum fixing device in connection with hose set and vibrator these components will be completely as sembled unless specified differently Spe cial transport conditions are not specified Packaging The packaging protects the unit from transport damages The material of the packaging has been selected b
9. e turn the throttle screw in clock location and actuate the 2 2 way ball valve wise direction until the fixing device can on the vacuum fixing device to generate be easily moved by hand Then start the the required vacuum in the suction cup vibrator by actuating the manual 3 2 way Check the vacuum fixing device for tight Slide valve on the hose set the full vacu and secure attachment um will be generated lf the fixing device can be loosened by hand you should increase the pressure e g on maintenance unit with pressure regulator Then start the vibrator by actuating the man ual 3 2 way slide valve on the hose set and adjust the lubricator p The vacuum fixing device can be operated with filtered compressed air or nitro gen For operation of certain vibrators a lubricated drive medium is specified IMPORTANT Adjust the lubricator while the vibrator is running Exact details concerning can be taken from the operating instructions for the vibrator a gt When relocating the vacuum fixing device with hose set HG S to another sur om face the economy air supply function must be readjusted or checked on the re IMPORTANT Strictor screw Checklist for commissioning 1 Secure the VAC against falling down 2 Check all hose connections before opening the air supply Turn on the compressed air if necessary Position the vacuum fixing device to the desired place Adjust the lubricator if present lf necessary adjust the req
10. er The vacuum fixing device must not be mounted on round components which have a smaller di ameter than permitted in chapter 3 Technical data 3 Technical data Type Generated Generated Weight Air Noise recommended vacuum suction consump level minimum diameter power tion for bar N kg l min dB A round containers mm 4 bar 6 bar 4 bar 6 bar 4 bar 6 bar 4 bar 6 bar VAC 8 HGI0N 0 0 0 85 34o 401 oss 40 60 72 72 mo VAC 8 HG10S 060 0 85 340 as 1 20 20 22 72 72 no VAC 10 HG10N 0 60 0 05 465 658 1 05 40 o 72 72 mo VAC 10 HG105 0 60 0 85 465 ess 1 90 20 22 72 72 no VAC 11 HG10N 0 60 0 85 710 1 005 1 25 40 60 74 74 mo VAC 11 HG105 0 60 0 85 710 1 005 1 60 20 22 74 74 110 VAC 12 HG15N 0 60 0 85 1 260 1 770 288 60 122 74 74 950 aC 12 HG 155 0 60 085 1260 1770 ao olya 74360 VAC 13 HG 15 N 0 60 0 85 1 362 1 930 VAC 15 HG 155 0 00 0 lt 5 1 962 s00 asl a sel 74 74 s0 VAC 15 HG 15N 0 60 0 85 1 476 2 001 340 110 170 74 74 650 VAC 15 HG158 0 60 0 05 1476 2 001 975 s sa ra 74 eo vac20 Ha15n oso o85 2724 8859 725 110 i70 7 74 s0 VAC 20 HG15 0 60 0 85 2 724 3 850 760 41 s2 74 74 sso VAC 90 HG 301N 0 60 0 85 4 086 5 769 11 60 mo i70 74 74 150 vaG 0 6305 0601085 4086 5762 1200 4 eolaj a 500 VAC 40 HG 40 N 0 60 0 85 5 448 7 718 20 00 Maximum suction power at 5 bar For operation of a vibrator a T pressure may be required
11. erature ranges with suction cups made of silicone Further information on request SPECIAL DESIGNS 12 Waste disposal The parts are to be correctly disposed of depending on the material Material specifications Aluminium Vacuum nozzle handgrip Clamping plate handgrip Rubber Suction cups Suction cups E E or anthracite black or anthracite Brass nickel plated nickel Brass nickel plated Fittings Vacuum nozzle Fittings nozzle Vacuum nozzle Fittings Special units Material on request e g suction cups made of silicone f All units can be disposed off through NetterVibration The valid disposal prices are available on request 13 Enclosures Further information available on request Leaflet no 15 VAC and more Rs 24
12. ere you can hook the safety rope of the vacuum fixing device to attach it on your container or your construction DANGER This rope must be pre tensioned as short as possible by using a rope clamp Should a vacuum fixing device come loose it must not drop into a slack rope Checklist for installation 1 Install the vibrator Mounting screws secure 2 Install hose set 3 Install maintenance unit filter regulator and lubricator possibly and valve Lock the fastening screws with glue e g Loctite Glue the air supply lines Observe the information on hose length and diameter Connect safety cable 20 7 Start up operation In case of an unexpected pressure drop the vacuum fix ing devices may come loose Therefore they are always secured against falling down For 8 VAC and 10 VAC additional adapter plates and safety ropes are available DANGER From series VAC 11 the vacuum fixing devices are fitted with an adjustable safety rope Handling Adjust the desired vibrator frequency First secure the vacuum fixing device with a pressure regulator option e g against falling down Then you have to part of a maintenance unit check the hose connections Turn on the When using a vacuum fixing device with compressed air supply for the vacuum fix hose set HG S you may activate the ing device and the vibrator Then attach Economy Air Supply function For this the vacuum fixing device to the desired purpos
13. l notes Information on the operating instructions Use and storage of the operating instructions Before use of the Vacuum fixing device of the series VAC read this operating manual carefully It is the basis for any action taken with regard to the VAC and may be used for training purposes The operating manual should subsequently be stored near the VAC 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 VAC 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 VAC 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 ill
14. minated compressed air In this case the nozzle must be disassembled and cleaned On VAC 8 VAC 10 VAC 11 and VAC 12 the externally vacuum nozzle is easy to disassemble and clean Disassembly and cleaning of vacuum nozzles on VAC 13 VAC 15 VAC 20 VAC 30 and VAC 40 should only be per formed by NetterVibration With a lubricator connected in series make sure that the lubri cator works as specified contents decreases number of drops min Fill oil if necessary Clean if necessary The maintenance intervals depend mainly on the purity of the drive medium and the ambient conditions Replace filter insert empty the filter when required or clean the filter insert wash out 22 9 Troubleshooting Fault Possible cause _ Trouble shooting Remedy Vacuum fixing devices slips during vibration Air supply Silencer on fixing device clogged Vacuum nozzle clogged Suction surface Air supply Silencer clogged Vacuum nozzle clogged Suction surface Suction worn Extremely massive rebounds cups base Check pressure before holder Hose set correctly assembled For economic air supply check setting of restrictor Hoses kinked Sufficient cross section of supply line Performance test without silencer Is the suction surface air permeable and or rough Hoses kinked Is the suction surface air permeable Is the suction surface oily greasy or wet 23 Adjust pressure to 3 bar to 6 bar A
15. n vibrator 11 4 Design and Functioning Vacuum fixing device A vacuum fixing device mainly consists of a base plate a 2 2 way ball valve a vacuum nozzle and suction cups When operating the 2 2 way ball valve the vacuum nozzle generates a vacuum By this the A suction cups of the vacuum fixing device adheres to TERRA the mounting surface by suction suction cups in this example 2x vacuum nozzle Functional unit Hose set vacuum fixing device and vibrator together form a functional unit The vibrator is tightly bolted to Vibrator the vacuum fixing device Vibrator and vacuum fixing device are supplied with the necessary energy com vonnection etween hose set pressed air or nitrogen through the hose set and compressed air source hose set The hose set is normally available in two different designs Hose set Standard HG N and hose set Economy Air Supply HG S Hose set HG N The vacuum fixing device opened main valve cus 3 2 way slide valve tomer will always be under pressure when the pressure is applied The vibrator is switched on and off by actuation of the manually operated 3 2 way slide valve Hose set HG S In addition to the standard function see hose set Standard HG N the hose set Economy Air 3 2 way slide valve Vibrator Supply HG S has an economy switch position With the vibrator switched off the compressed air
16. orrect position For assembly of the PKL 740 to the VAC 15 an adapter plate is required if the IMPORTANT inlay EE is not used Template VAC 13 107 5 PKL 2100 PKL 5000 50 PKL 740 107 5 PKL 2100 PKL 5000 72 NTS 75 01 NTS 50 01 gha Do not drill through this aerea Template VAC 15 100 PKL 740 72 NTS 50 01 75 01 51 NTP 32 Do not drill through this aerea NTS 250 350 NTK 18AL 25 Te N s gt S Ww J 2 a N f m 145 78 NTP 48 104 NCB10 20 NCR22 NCT15 29 130 NCB50 70 NCR57 NCT55 108 Template VAC 20 2 5 A O c aa 90 NTS 54 02 NTS 70 02 51 NTP32 NTS 70 02 Round Plate Do not drill through this aerea 90 NTS 54 02 NTS 70 02 91 NTP 32 NTS 70 02 T i F vl Ols ao W 1 p bat NS _ w lt p CL oy oy EN gt p DO y 78 NTP 48 107 5 PKL 2100 PKL 5000 124 NTS 50 04 17 Template VAC 30 152 PKL2100 PKL5000 70 NVG 49 55 61 165 NTS 50 08 Do not drill through this aerea 180 NVG 82 84 200 NVG 49 55 61 124 NTS 50 04 VAC 40 Installation of the Vibrator The VAC 40 consists of two VAC 20 which are connected by an adapter plate The vibrator is mounted to the adapter plate For the fastening of a compressed air op erated piston vibrator series NTS 50 10 the Installation of the VAC on the lifting device Due to its own
17. ssemble hose set correctly Adjust restrictor Route hoses Enlarge the cross section kinks line without supply Wash out or replace as required Clean procedure is described in chapter Maintenance and Repair lf yes the vacuum fixing device is not suitable for this application Route hoses without kinks Wash or replace Clean procedure is described in chapter Maintenance and Repair lf yes the vacuum fixing device is not suitable for this application Remove the respective layers Replace suction cups Mount fixing device to the elastic base between stiffeners diaphragm effect 10 Spare parts When ordering spare parts please give the following details 1 Required quantity 2 Description and position of the spare part see spare parts list 3 Type of unit 11 Accessories The r accessories are available for vacuum ee devices on request Description Hose material and fittings emer n decharge Gt Comores sed Bir r ANo ES supply and discharge of compressed air in various qualities and dimensions 3 2 or 2 2 way valves For electric pneumatic and manual control E E For rotary speed control manually adjustable or pneumatically controllable for remote control Filter regulator lubricator Duty pause control Electric or pneumatic for interval operation Some vacuum fixing devices are also available as special ver sions e g with stainless steel plate for extreme temp
18. uired frequency on the pressure regulator 7 The compressed air feed lines the plug screws and the fixing screws have to be tightened and checked 3 4 5 6 21 8 Service Maintenance CAUTION IMPORTANT Before starting inspection and service works shut off the compressed air supply and secure it against unintended 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 For more details refer to the operating lt 5 um instructions for the relevant vibrator Recommendation Filter Maintenance plan Maintenance must be performed monthly DANGER Screw con nections Securing rope Cleaning Suction cups Vacuum nozzle Lubricator Silencer Filter of the maintenance unit The screw connections must be checked after an hour of operation after first startup then at regular intervals and if necessary be tightened and secured with Loctite lf the safety rope has been extremely loaded by the vacuum fixing device dropping down it should be replaced by a new one Vacuum fixing devices may be cleaned from outside with oressurized water After cleaning run the unit for a short moment The suction cups must be permanently checked for wear and need to be replaced if necessary The vacuum nozzle may be clogged by conta
19. ustrations and descriptions 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 CAUTION referring to a possible risk which if not avoided can result in serious injury and 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 VAC Special features Netter vacuum fixing devices of series e Quick mounting without bolting or VAC for pneumatic vibrators are in strict welding compliance with the EC Machine Di e Strong connection due to high vacuum rective 2006 42 EC The standard DIN e Can also be used on curved and une EN 12100 has been observed in particu ven surfaces lar e optional air economizer 2 Safety Designated use Vacuum fixing devices of series VAC are used for quick fastening
20. weight the vacuum fixing device may only be lifted with suitable lifting adapter plate has four through holes For the fastening of any other vibrator you should consult NetterVibration beforehand device When lifting the vacuum fixing de vice an eyebolt M16 is available Vacuum fixing devices should be used in combination with the following hose sets VAC 8 JHGI0NorHG 10S J S VAC 10 HG 10 N or HG 10 S HG 15 N or HG 15 S HG 10 N or HG 10 S VAC 40 IHG AON gt S O Throttle control valves DRV are recommended for use of a hose set Example of Hose set HG N with DRV Manual slide valve DRV connection connection Compressed Vibrator air Supply connection Vacuum fixing devices connection Vibrator connection connection Compressed Vacuum fixing air supply devices throttle screw air economizer function Connection of power supply Supply line The pressure loss increases with the hose supply lines we recommend the use of big length The following recommendations re ger cross sections whereby the supplied fer to hose lengths of max 3 m to the next hose socket can no longer be used bigger hose cross section For longer Minimum cross sections for hoses A A too small cross section does not enable a sufficient vacuum CAUTION Type Hose socket Hose size HG10N S HG15N S HG 30N S Safeguard with safety rope Before mounting locate a secure attachment point e g an eye bolt wh
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