Operating instructions for Netter pneumatic impactors of the series PKL These operating instructions apply to: PKL 190 PKL 450 PKL 740 Sept. 2017 No.
Contents 1 General information 3 2 Safety 5 3 Technical data 7 4 Design and function 10 5 Transport and storage 11 6 Installation 12 7 Start-up and operation 21 8 Maintenance and servicing 22 9 Troubleshooting 23 10 Spare parts and accessories 24 11 Disposal 25 12 Annex 26 Scope of delivery Please refer to the delivery note for the scope of delivery. Check the packaging for possible transport damage.
General information 1 General information Use and storage Before installing the PKL read these operating instructions carefully. It is the basis for any action when dealing with the PKL, and may be used for training purposes. The operating instructions should be subsequently stored at the operation site. Target group The target group for these operating instructions is technical staff, who have basic knowledge in pneumatics and mechanics.
General information Instruction and warning symbols Personal injuries The following instruction and warning symbols are used in these operating instructions: DANGER signifies an immediate danger. Disregard of this notice will result in death or severe bodily injuries. WARNING signifies a potential danger. Disregard of this notice can result in death or severe bodily injuries. CAUTION signifies a potentially dangerous situation. Disregard of this notice can result in minor or moderate bodily injuries.
Safety 2 Safety Intended use General areas of application of the PKL are for knocking off adhesive bulk materials from container walls (e.g. silos, hoppers, filter outlets, pipelines and reactors) and for emptying residues from weighing containers. The PKL also prevent bridging and rat-holing, so that the material can continuously flow. The PKL can be used outdoors and in dusty environments, however not in water or any other liquids. PKL may only be operated with a timed on/off sequence.
Safety Compressed air WARNING Compressed air A loosened hose which is under pressure can lead to personal injuries. Screw the hose lines on carefully. Check the hose lines and connections after one hour of operation and thereafter regularly (generally monthly). Retighten the hose lines, if necessary. Ensure that the compressed air is disconnected from the supply lines during all work on the PKL. Prevent the PKL from being switched back on during all work.
Technical data 3 Technical data Parameters Type: PKL... Weight of piston Force of impact * Air consumption/impact at optimum pressure [Nl] Overall weight [kg] Optimum operating pressure [bar] [kg] 190/4 0.19 0.43 4.0 0.20 0.8 1-2 190/6 0.19 0.60 6.0 0.20 0.8 1-2 450/4 0.44 0.56 4.0 0.40 1.6 1-3 450/6 0.44 0.92 6.0 0.60 1.6 1-3 740/3 0.74 1.30 3.0 0.50 2.6 2-4 740/4 0.74 1.80 4.0 0.70 2.6 2-4 740/5 0.74 2.10 5.0 0.80 2.6 2-4 740/6 0.74 2.70 6.
Technical data Noise level The noise level of the PKL may exceed 80 dB(A) (single noise incident). Depending on the impact sequence the continuous noise level is below this value. The PKL should be preferably mounted with the EE kit. The noise reduction is about ca. 5 dB(A) (single noise incident). The sound emitted by the PKL can be dampened by hoods (on request). This is only worthwhile if the impacted sheet metal is also insulated (e.g. by heat insulation material).
Technical data Dimensions PKL 2100 / 5000 / 10000 PKL 2100 PKL 5000 PKL 10000 Type: PKL... A [mm] B [mm] C [mm] ØD [mm] E [mm] F G [mm] H [mm] 2100 Ø120.0 Ø180 17 13.0 - Ø152 300.5 5000 Ø114.3 Ø180 22 17.0 - G 1/8, NW 6 × 1 Ø152 376.5 10000 Ø 145.0 Ø220 25 17.0 - Ø185 445.
Design and function 4 Design and function Design 1 2 3 4 5 6 Quick air-exhaust valve Silencer Springs Piston Flange Impact plate p F Compressed air Impact force Function The PKL is a pneumatic „hammer“. Compressed air (p) goes under the piston (4) and presses it against one or two springs (3). When exhausting, the air chamber beneath the piston empties abruptly via the quick air-exhaust valve (1).
Transport and storage 5 Transport and storage Transport conditions Special transport conditions are not required. When moving the PKL 10000, use the mounted transport lugs at the top of the housing. Packaging The PKL are packed and ready for assembly. Accessories and add-on parts are delivered unmounted, unless otherwise agreed upon. The packaging protects the PKL from transport damage.
Installation 6 Installation Safety instructions IMPORTANT Observe the safety instructions in Ch. Safety, page 5. Procedure When installing the PKL carry out the following steps in succession: Instructions for EE kit PKL 190 / 450 / 740 Install the EE kit on the PKL 190 / 450 / 740 between the flange of the PKL and the mounting surface so that • • the piston of the PKL strikes the elastomer disc (1). the O-ring (3) is between the spacer plate (2) and the mounting surface.
Installation Instructions for EE kit PKL 2100 / 5000 Install the EE kit on the PKL 2100 / 5000 as follows: 1. Remove the steel impact plate with the O-ring (2) and the damper ring (impact plate, 1). 2. Insert the EE impact plate with the O-ring (3) in such a way that the piston of the PKL strikes against the EE impact plate (3). Ensure that the damper ring (flange, x) is between the flange of the PKL and the mounting surface.
Installation Fastening devices NetterVibration delivers the appropriate fastening devices for installation of the PKL: weld-on consoles or weld-on plates (±0.3 mm flatness) • • Weld the consoles directly onto the container walls. Weld the plates onto previously mounted saddle plates (1.5 times the sheet thickness of the container).
Installation Instructions fastening kit Components of the fastening kit using the example NBS D: 1 2 3 4 5 6 7 Hexagon bolt NBS lock plate Washer Damper spring Washer (only for NBS D) Tab washer with long tap (only with NBS D) Nut (only for NBS D) The damping springs must be mounted on the flange of the PKL. 1. Tighten the screw connections evenly, until the damping springs are completely pressed together. 2. Loosen the screw connections by one revolution.
Installation Instructions for ST kit The ST kit connects the control port to the piston chamber. The PKL equipped with the ST kit strikes as long as there is compressed air. • • • • For PKL 190 / 450 proceed as follows: - Mount the ST screw fitting (after the NBS). - A 3/2-way valve with air supply is necessary. For PKL 740 proceed as follows: - Replace the silencer with the compressed air connection. - Only one air supply is necessary. Order the PKL 2100 directly with the ST control.
Installation Standard installation PKL 190 / 450 / 2100 / 5000 / 10000 Example: PKL 450 1 2 3 4 Electronic Timer AP Ball valve Maintenance unit 3/2-way valve Standard installation PKL 740 1 2 3 4 5 6 Use a 3/2-way valve (4) for actuation. By switching the valve, the piston chamber is vented and exhausted and the PKL therefore strikes. Mount the 3/2-way valve (4) at a distance of max. 15 m.
Installation Installation with long supply line PKL 190 / 450 / 2100 / 5000 Example: PKL 450 1 2 3 4 5 Installation of several PKL 18 Electronic Timer AP Ball valve Maintenance unit Actuating valve on customer's site 3/2-way air valve Example: PKL 450 1 2 3 4 5 The main air is always at the 3/2-way air valve (5) max. 1 m away from the PKL. The control line from the actuating valve (4) on the customer's site to the PKL may be longer (e.g. 50 m).
Installation Installation with ST kit PKL 190 / 450 / 2100 / 5000 / 10000 Example: PKL 450 1 2 3 4 5 6 The PKL, equipped with an ST kit (1), strikes as long as pressure is applied. The PKL thereby achieves a maximum impact frequency of up to one strike/second, which must be reduced to the permissible impact frequency (e.g. with a non-return throttle valve (5) inserted in the supply line). A 3/2-way valve (6) enables operation of the PKL equipped with an ST kit at a larger distance (up to 50 m).
Installation Installation with coupling to other functions Example: PKL 2100 1 2 3 4 Checklist installation If the PKL is equipped with an ST kit, then it can be coupled with another function without a control or a pulse generator. The adjacent illustration shows the coupling with an opening cylinder (3) of a weighing container. The PKL is now not actuated. When opened, it strikes at the set number of cycles on the non-return throttle valve (4), as long as the flap is open.
Start-up and operation 7 Start-up and operation Safety instructions IMPORTANT Observe the safety instructions in Ch. Safety, page 5. Permissible operating conditions Please refer to Ch. Technical data, page 7 for permissible operating conditions. Design of mist lubricator When selecting the mist lubricator, take into consideration that the air consumption of the PKL is very low. The choice of mist lubricator depends on how many PKL are operated simultaneously.
Maintenance and servicing 8 Maintenance and servicing Safety instructions IMPORTANT Observe the safety instructions in Ch. Safety, page 5. Maintenance plan Maintenance of the PKL must be carried out as follows: Interval Action After one hour of operation after initial commissioning Check fastening and locking screws. Monthly Check fastening and locking screws. Check hose screw connections and hose connections and retighten, if necessary.
Troubleshooting 9 Troubleshooting Disturbances and causes In the case of disturbances of the PKL proceed as follows: Possible causes Troubleshooting Corrective actions Disturbance: does not function Mounting surface not flat Loss of pressure via O-ring? Establish ±0.3 mm flatness on mounting surface. Malfunction of valve and control Check PKL without valve and control. Check 3/2-way valve and control, and replace if necessary. Air supply Check pressure. Set operating pressure.
Spare parts and accessories 10 Spare parts and accessories Ordering of spare parts Possible accessories Please provide the following details when ordering spare parts: • • • required amount description and position of spare part type designation of PKL Following accessories for the PKL are available: Component Description NBS fastening sets Compulsory for safe and permanent mounting (see Ch.
Disposal 11 Disposal Disposal costs Material specifications All parts of the PKL must be properly disposed of according to the material specifications. The valid disposal costs of the PKL are available on request.
Annex 12 Annex 26
