NetterVibration PKL Series User manual

Operating instructions for
Netter pneumatic impactors
of the series PKL
June 2020
No. 1468E
Page 1/26
These operating instructions apply to:
PKL 190
PKL 450
PKL 740
PKL 1000
PKL 2100
PKL 5000
PKL 10000

2
Contents
1General information 3
2Safety 5
3Technical data 7
4Design and function 10
5Transport and storage 11
6Installation 12
7Start-up and operation 21
8Maintenance and servicing 22
9Troubleshooting 23
10 Spare parts and accessories 24
11 Disposal 25
12 Annex 26
Please refer to the delivery note for the scope of delivery.
Check the packaging for possible transport damage. In the event of
damage to the packaging, check the contents for completeness and
possible damage. Inform the carrier in the case of damage.
The pneumatic impactors of the series PKL are hereafter referred to as
"PKL".
Document no.
1468E
Version no.
4
Date of issue
June 2020
Scope of
delivery
Designation
Version of
document

General information
3
1 General information
Before installing the PKL read these instructions carefully. It is the basis
for any action when dealing with the PKL, and may be used for training
purposes. The instructions should be subsequently stored at the operation
site.
The target group for these instructions is technical staff, who have basic
knowledge in pneumatics and mechanics.
Only complying technical staff may work on the PKL.
The PKL may only be installed, put into operation, maintained, troubleshot
and disassembled by persons authorised by the operator.
This documentation is protected by copyright.
Netter Vibration reserves all rights such as translations, reprinting and re-
production of the instructions, as well as parts thereof.
All technical information, data and instructions for installation, operation
and maintenance in these instructions are based on the latest information
available at the time of printing and take our past experience to the best of
our knowledge into account.
No claims can be derived from the information, illustrations and descrip-
tions in these operating instructions.
The manufacturer does not assume liability for damages resulting from:
•failure to observe the instructions,
•improper use,
•unauthorised repairs,
•technical modifications,
•use of non-permissible spare parts.
Translations are made to the best of our knowledge.
Netter Vibration does not assume liability for translation errors, even if the
translation was made by us or on our behalf. Only the original German text
remains binding.
The pneumatic impactors of the series PKL comply with the EC Machinery
Directive 2006/42/EC.
In particular, the standard EN ISO 12100 has been observed.
Use and
storage
Target group
Copyright
Limitation of
liability
Directives /
standards
observed

General information
4
The following instruction and warning symbols are used in these instruc-
tions:
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.
NOTICE
signifies potential material damage.
Disregard of this notice can result in material damage.
IMPORTANT
indicates actions, methods or notes that are not relative to safety, e.g. use-
ful information and tips.
Environmentally safe disposal
indicates the obligation of environmentally safe disposal.
Instruction
and warning
symbols
Personal
injuries
Material
damages
Notes

Safety
5
2 Safety 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 continu-
ously flow.
The PKL can also be used outdoors as well as in dusty or dump environ-
ments, however not in water or any other liquids.
PKL may only be operated with a timed on/off sequence.
Any other use is considered improper.
Installation, commissioning, maintenance and troubleshooting of the PKL
may only be performed by authorised qualified personnel.
All handling of the PKL is the responsibility of the operator.
WARNING
Falling parts
The PKL, construction parts as well as fastening screws can
come loose due to vibration. Falling parts can lead to severe
personal injuries.
➢Use only Netter fastening kits (NBS) to fasten the PKL.
➢The PKL 190, PKL 450 and PKL 740 are open on the
side of impaction. During installation ensure that the im-
pact piston remains in the housing.
➢Mount the PKL 1000, PKL 2100, PKL 5000 and
PKL 10000 additionally with an impact plate and two
damper rings (flange and impact plate) or with an EE kit
and a damper ring (flange).
➢Check the fastening screws after one hour of operation
and thereafter at regular intervals (generally monthly).
➢Retighten the fastening screws, if necessary.
➢A safety device with a safety cable is mandatory for criti-
cal mounting situations.
Intended use
Qualification
of qualified
personnel
Falling parts

Safety
6
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.
WARNING
Sound level
Near the PKL or near constructions connected to the PKL E
the sound pressure level may exceed 80 dB(A). Human
hearing can be permanently damaged by high noise levels.
➢Use hearing protection during work in a noisy area if
80 dB(A) is exceeded.
➢Mount the PKL preferably with an EE kit.
WARNING
Risk of injury while handling heavy parts
Risk of serious injury due to weight during transport and installation of the
PKL.
➢Observe the weight information in Chapter Technical data, from page 7
on.
➢Only qualified personnel may transport and install the PKL.
➢Use suitable load handling devices and slinging equipment.
➢Wear suitable personal protective equipment.
CAUTION
Loose parts
The PKL are not mechanically closed on the side of impact. The impact
piston and/or the impact plate are loosely mounted. Falling parts can lead
to personal injuries and material damage.
➢Ensure that the impact piston and/or impact plate remain in the housing
when mounting and dismantling.
Compressed
air
Sound level
Heavy parts
Loose parts

Technical data
7
3 Technical data
Drive
medium
The PKL must be operated with clean compressed air or nitrogen, prefer-
ably oiled, according to the following specification:
ISO 8573-1
[ 5
:
6
:
4 ]
Filter ≤ 5 µm
Humidity,
pressure dew point ≤ +10 °C
Total oil content
≤ 5 mg/m3
Lubrication
ISO viscosity class in accordance with DIN ISO 3448, VG 5 to 15
Fill mist lubricator with acid- and resin-free compressed air oil.
Recommendation for temperatures
of up to 60 °C:
Klüber "AIRPRESS 15"
Recommendation for temperatures
over 60 °C with HT-versions:
Aral "Farolin U" lubrication oil
Ambient
temperature*
Standard: -20 °C to 60 °C
HT versions: -5 °C to 160 °C de-
pending on version
Operating
pressure*
2.5 to 7.0 bar
The actual air pressure set on the regulator must not exceed the optimum
operating pressure by more than 1 bar.
Impact
frequency
The following impact sequence must not be exceeded:
Maximum 10 strokes in sequence at an impact frequency of
15 strokes/min and 180 strokes/h.
* Higher operating pressures and temperatures are permitted only after consultation with and written consent
by the application technicians of NetterVibration.
The type designations of the PKL have the suffix /3, /4, /5 or /6. The suffix
is derived from the optimum operating pressure, i.e. the PKL 740/4
achieves the optimal effect at an operating pressure of 4 bar. In this case,
increasing the pressure does not increase the impact energy.
Special versions for operating under temperatures outside the standard
temperature range are additionally marked with HT for high temperature or
NT for low temperature.
The sound pressure level of the PKL may exceed 80 dB(A) (single sound
incident). Depending on the impact sequence the continuous sound level
is below this value.
The PKL should be preferably mounted with the EE kit. The reduction of
the sound pressure level is about ca. 5 dB(A) (single sound incident).
The sound emitted by the PKL can be dampened by coverings. The sound
pressure level is reduced only with simultaneous insulation of the applied
sheets.
Permissible
operating
conditions
Type
designation
Sound level

Technical data
8
Type:
PKL ...
Weight
of piston
[kg]
Force of
impact *
[kg]
Optimum
operating
pressure
[bar]
Air consump-
tion/impact at opti-
mum pressure
[Nl]
Overall
weight
[kg]
Suitable
for wall
thickness
of...
[mm]
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
6.0
1.00
2.6
2 - 4
1000/4
1.00
2.80
4.0
2.70
5.7
2 - 4
1000/6
1.00
4.30
6.0
4.00
5.8
3 - 5
2100/4
2.10
4.20
4.0
5.20
6.7
3 - 5
2100/5
2.10
6.20
5.0
6.50
6.9
3 - 5
5000/4
4.96
6.60
4.0
5.70
16.0
4 - 8
5000/6
4.96
10.60
6.0
8.60
16.5
6 - 12
10000/6
10.00
17.50
6.0
15.10
34.0
> 10
* The force of impact corresponds to the impact of the given weight falling from a height of 1 m.
PKL 190
PKL 450
PKL 740
Type:
PKL ...
A
[mm]
B
[mm]
C
[mm]
Ø D
[mm]
E
[mm]
F1
G
[mm]
H
[mm]
H*
[mm]
190
38.0
111
15
9.0
-
G 1/8,
DN 6 × 1
90.0
163.5
169.5
450
73.5
126
14
13.0
-
90.0
192.0
200.0
740
90.0
140
15
13.0
50
100.0
238.5
248.5
* with EE kit 1DN = nominal diameter
Parameters
Dimensions
PKL
190 /
450 /
740

Technical data
9
PKL 1000
PKL 2100
PKL 5000
PKL 10000
Type:
PKL ...
Ø A
[mm]
Ø B
[mm]
C
[mm]
Ø D
[mm]
E
[mm]
F1
Ø G
[mm]
H
[mm]
1000
88.9
140
13
13
-
G 1/8,
DN 6 × 1
116
266
2100
120.0
180
17
13.0
-
152
300.5
5000
114.3
180
22
17.0
-
152
376.5
10000
145.0
220
25
17.0
-
185
445.0
1DN = nominal diameter
Dimensions
PKL
1000 /
2100 /
5000 /
10000

Design and function
10
4 Design and function
1
Quick air-exhaust valve
2
Silencer
3
Springs
4
Piston
5
Flange
6
Impact plate
p Pressure
F Impact force
The PKL is a pneumatic "hammer". Compressed air goes under the pis-
ton (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).
The piston (4) (hammer) is struck by the spring force against an impact
plate (6), which then passes the impact force (F) on. For PKL without an
impact plate (PKL 190, PKL 450 and PKL 740), the piston strikes directly
against the fastening surface. The PKL 1000, PKL 2100, PKL 5000 and
PKL 10000 have an impact plate.
The air escapes via the silencer (2).
The PKL only work when mounted, as the piston chamber is then sealed
by a built-in O-ring in the mounting surface (until PKL 740) or by a damper
ring (flange; from PKL 1000 on).
A quick-air exhaust valve and a 3/2-way valve are integrated in the valve
head of the PKL 740. Therefore, the control valve on the customer's site
can be mounted at any distance away from the PKL 740.
The control air must be connected at the side. A silencer is mounted on
the exhaust air outlet.
The ST kit allows a continuous impact sequence with permanent com-
pressed air supply.
The EE kit generates a "rubber hammer effect" and reduces the noise lev-
el.
Design
Function
Features of
PKL 740
ST kit
EE kit

Transport and storage
11
5 Transport and storage
Observe the safety instructions in Ch. Safety, from page 5 on.
Special transport conditions are not required.
When moving the PKL 10000, use the mounted transport lugs at the top of
the housing.
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. The packaging
material has been selected from an environmentally safe and technically
disposable point of view and is therefore recyclable.
The return of packaging to the material cycle conserves raw materials and
reduces the amount of waste.
1
Plastic fastening
2
Damper ring (impact plate)*
* for steel impact plate
3
Impact plate
4
Corrugated cardboard disc
5
Damper ring (flange)
The PKL 1000, PKL 2100, PKL 5000 and PKL 10000 are delivered with a
transport safety device at the bottom. The transport safety device consists
of two plastic fastenings (1) and a corrugated cardboard disc (4). It pre-
vents the impact plate (3) from falling out during transport and must be
removed before installation. Take care that the impact plate and damper
ring (flange; 5) retain their position on the PKL, as they must be mounted
with the PKL.
•Store the PKL in a dry and clean environment.
•Protect the PKL from UV-exposures, weather and ozone.
•The storage temperature is between -20 °C and +60 °C.
•Close all openings when re-storing.
•Preserve the PKL before storage:
1. Mount the PKL on a plate. The impact plate of the PKL 1000,
PKL 2100, PKL 5000 and PKL 10000 must be inserted.
2. Apply anti-corrosion oil to the air inlet and briefly activate the PKL.
Transport
conditions
Packaging
Transport
safety device
PKL
1000 /
2100 /
5000 /
10000
Storage
conditions

Installation
12
6 Installation
Observe the safety instructions in Ch. Safety, from page 5 on.
When installing the PKL carry out the following steps in succession:
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 sur-
face.
The spacer plate is supplied with the O-ring mounted.
EE kit:
1
Elastomer disc
2
Spacer plate
3
O-ring
Example: PKL740
For detailed information, please refer to the mounting instructions for the
respective PKL type.
Procedure
Instructions
for EE kit
PKL
190 /
450 /
740

Installation
13
Install the EE kit on the PKL 1000 / 2100 / 5000 / 10000 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.
1
Damper ring
(impact plate)
2
Steel impact plate with O-ring
x Damper ring (flange)
3
EE kit:
EE impact plate with O-ring
x Damper ring (flange)
Example: PKL 2100
For detailed information, please refer to the EE kit mounting instructions
for the respective PKL type.
Instructions
for EE kit
PKL
1000 /
2100 /
5000 /
10000

Installation
14
Appropriate fixing devices (±0.1 mm flatness):
weld-on consoles, weld-on plates, glueing consoles
•Weld the weld-on consoles directly onto the container walls.
•Weld the plates onto previously mounted saddle plates (1.5 times the
sheet thickness of the container).
•Glue the glueing consoles directly to container walls.
Examples:
Weld-on console, plane
Weld-on console, round
Weld-on plate
Glueing console, conical
1
Saddle plate
2
Weld-on plate
1
Glueing console
For safe and permanent fixation of the PKL to the fixing device use the
compulsory fastening kits.
The following fastening kits are available for every PKL type:
Description
Difference
NBS ... G (e.g. NBS 5000 G)
For tapped hole
NBS ... D (e.g. NBS 740 D)
For through-hole
NBS ... (e.g. NBS 190)
Without screws
... corresponds to the PKL type: 190 / 450 / 740 / 1000 / 2100 / 5000 / 100001
Fixing
devices
Fastening
kits NBS

Installation
15
Components of the fastening kit using the
example NBS D:
1
Hexagon bolt
2
NBS lock plate
3
Washer
4
Damper spring
5
Washer
(only for NBS D)
6
Tab washer with long tap
(here only for NBS D)
7
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.
Then fold all protruding roundings
of the lock plates towards all bolt
heads, with NBS D also towards all
nuts, as follows:
For NBS D fold all long taps of the
tab washers towards the mounting
plate.
For detailed information, please refer to the respective Mounting Instruc-
tions (NBS G mounting kits or NBS D mounting kits).
Instructions
fastening kit
NBS

Installation
16
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.
•For PKL 5000 proceed as follows:
-Mount the control valve of the ST control to the PKL.
-The control valve is connected internally to the piston chamber, the
ST control is integrated in the PKL.
For detailed information, please refer to the Assembly Instructions for the
ST kit.
For all installations, use a ball valve to shut off the main line and a mainte-
nance unit.
The maintenance unit should comprise a filter, a regulator and a mist lubri-
cator (see page 7; "Drive medium").
Connect the PKL with the pneumatic hose according to the following de-
picted pneumatic circuit diagrams.
Define the impact sequence of the PKL with an electrical control, e.g. the
Netter Electronic Timer AP 117.
Recommended cross-sections for control lines, control valves and main air
supply: DN 6 × 1
To connect the control valve to the PKL:
•DN 6 should be used and
•a length of 15 m should not be exceeded.
For simultaneous operation of several PKL
•larger cross-sections are to be provided for the main line up to distribu-
tion to the individual PKL.
•the total length of the compressed air supplies is max. 50 m.
Instructions
for ST kit
Components
for all
installations
Specifications
for valves and
hoses

Installation
17
Example: PKL450
1
Electronic Timer AP
2
Ball valve
3
Maintenance unit
4
3/2-way valve
Use a 3/2-way valve (4) for ac-
tuation.
By switching the valve, the pis-
ton chamber is vented and ex-
hausted and the PKL therefore
strikes.
Mount the 3/2-way valve (4) at a
distance of max. 15 m.
1
Electronic Timer AP
2
Ball valve
3
Maintenance unit
4
Actuating valve on customer's site
5
Control line
6
Main air
The PKL 740 is the only PKL
with a 3/2-way valve integrated
in the valve head.
By switching the valve, the pis-
ton chamber is vented and ex-
hausted and the PKL therefore
strikes.
The main air (6) is present at
the valve head. The control line
(5) from the actuating valve on
the customer's site (4) to the
PKL may be very long (e.g.
50 m). The charging time of the
PKL is several seconds for
longer supply and control lines.
For long air lines, set a pause
and duty time on the Electronic
Timer AP (1) to a minimum of at
least 5 s. If shorter lines are
used, reduce these times ac-
cordingly, e.g. to 2-3 s.
Standard
installation
all types of
PKL except
740
Standard
installation
PKL 740

Installation
18
Example: PKL450
1
Electronic Timer AP
2
Ball valve
3
Maintenance unit
4
Actuating valve on customer's site
5
3/2-way valve (pneumatic)
The main air is always at the
3/2-way 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).
For longer supply and control
lines, the charging time of the
PKL is several seconds. For
long air lines, set a pause and
duty time on the Electronic Tim-
er AP (1) to a minimum of at
least 5 s. If shorter lines are
used, reduce these times ac-
cordingly, e.g. to 2-3 s.
Example: PKL450
1
Electronic Timer AP
2
Ball valve
3
Maintenance unit
4
Actuating valve on customer's site
5
3/2-way valve (pneumatic)
It is possible to operate several
PKL in parallel with just one con-
trol and an actuating valve (4).
The connection lines from the
3/2-way valve (5) to the PKL must
be max. 1 m long, otherwise the
membrane in the PKL moves too
slowly and does not reach the
end position.
If required, install the actuating
valve (4) at a larger distance if
additional 3/2-way valves (5) are
used.
If several PKL are in operation,
the supply line must not be longer
than 50 m.
Installation
with long
supply line
all types of
PKL except
740
Installation
of several PKL

Installation
19
Example: PKL 2100
1
PKL with ST kit
2
Electronic Timer AP
3
Ball valve
4
Maintenance unit
5
Non-return throttle valve
6
3/2-way valve
The PKL, equipped with an ST
kit (1), strikes as long as pressure
is applied. The PKL thereby
achieves a maximum impact fre-
quency of up to one strike per
second, which must be reduced
to the permissible impact fre-
quency (see Ch. Technical data,
page 7, e.g. with a non-return
throttle valve (5) inserted in the
supply line).
A 3/2-way valve (6) enables op-
eration of the PKL equipped with
an ST kit at a larger distance (up
to 50 m).
1
ST kit
2
Electronic Timer AP
3
Ball valve
4
Maintenance unit
5
Non-return throttle valve
6
2/2-way valve
The PKL 740, equipped with an
ST kit (1), strikes as long as pres-
sure is applied.
The PKL 740 thereby achieves a
maximum impact frequency of up
to one strike per second, which
must be reduced to the permissi-
ble impact frequency (see Ch.
Technical data, page 7; e.g. with
a non-return throttle valve (5) in-
serted in the supply line).
A 2/2- or 3/2-way valve (6) ena-
bles operation of the PKL 740
equipped with an ST kit at a larg-
er distance (up to 50 m).
Installation
with ST kit
PKL
190 /
450 /
2100 /
5000
Installation
with ST kit
PKL 740

Installation
20
Example: PKL2100
1
Ball valve
2
Maintenance unit
3
Opening cylinder
4
Non-return throttle valve
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 con-
tainer.
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 of the weighing
container is open.
Check that the following steps have been carried out:
Permissible ambient temperatures observed?
Fixing device mounted?
PKL mounted onto the fixing device (±0.1 mm flatness) with
NBS fastening set?
PKL 1000, PKL 2100, PKL 5000 and PKL 10000 additionally
mounted with damper ring (flange)?
Ball valve, maintenance unit (filter, regulator, mist lubricator),
valve and supply line mounted?
Information on hose length and nominal width observed?
Fastening screws secured with liquid safety agent, if re-
quired?
Hose lines sealed with liquid sealant, if required?
PKL in critical assembly situations secured against falling by
means of a safety cable?
Installation
with coupling
to other
functions
Checklist
installation