Assembly and Operating Instructions for Netter Pneumatic External
Contents
1. NetterVibration N A Assembly and Operating Instructions Oct 2010 for Netter Pneumatic External Vibrators BA No 879E Series NVG NVR NVT Page 1 16 These operating instructions apply to Series NVG Series NVR Series NVT Important note Before use of the pneumatic linear vibrators series NVG NVR and NVT read this operating instruction carefully and store afterwards Netter GmbH does not assume liability for damage to property and persons if the product has been technically modified or if the notes and regulations of these operating instructions have not been observed This documentation is copyrighted All rights e g for translation into other languages reprinting and copying of these operating instructions or parts hereof remain strictly reserved Netter GmbH www NetterVibration com Germany Fritz Ullmann Stra e 9 55252 Mainz Kastel Tel 49 6134 2901 0 Fax 49 6134 2901 33 info NetterVibration de Switzerland Poland Erlenweg 4 Al W Korfantego 195 17 4310 Rheinfelden 40 153 Katowice Tel 41 67 8316200 Tel 48 32 2050947 Fax 41 61 8311291 Fax 48 32 2051572 info NetterVibration ch info NetterVibration pl Table of Contents 1 GENERAL NOTES 2 TECHNICAL DATA 3 DESIGN AND FUNCTION 4 SAFETY 5 TRANSPORT AND STORAGE 6 INSTALLATION 7 START UP OPERATION 8 SERVICE MAINTENANCE 9 TROUBLESHOOTING 10 SPARE PARTS 11 APPENDIX 11 1 Accessories 11 2 Disposal 11 3 Enclosures Scope of delivery2. the vibrator starts properly the vane is free The exhaust air holes are in position below right In this position the vibrator do not start the inner rotor is lying on the vane The exhaust air holes are in position above left 4 Safety NVG NVR and NVT vibrators work with compressed air Make sure the compressed air supply is switched off during installation Disconnect the supply lines quick coupling before starting other work on vibrators and supply lines Before starting operation all hoses must be tightly connected A pressurized hose coming loose can cause severe injury Vibrators as well as parts of the structure may come loose because of vibration Falling parts can cause damage to persons and material 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 each month In critical installation situations the unit must be secured with a steel rope Sound level During the operation the sound level of the vibrators exceeds 85 dB A ear protectors are required Due to their high power the external vibrators NVG NVT and NVR have a sound level higher than 85 dB A especially if they are mounted on plates molds etc A sound insulation of the unit is only useful if plates and formwork panels are also insulated Pressure reduction reduces the
3. 12 13 14 Check the packaging for possible signs of transport damage In the event La of damage to the packaging check that the contents are complete and ae undamaged If there is any damage inform the shipping agent Compare the scope of the delivery with the delivery note 1 General notes Pneumatic external vibrators of series NVG NVR and NVT comply with the EC machine regulation 2006 42 EG In particular standards DIN EN ISO 12100 part 1 and 2 have been observed The vibrators generate non directed vibrations General areas of application are Loosening conveying sorting compacting and separating of bulk materials and reduction of friction NVG NVR and NVT vibrators are used for the compaction of concrete to empty bunkers to drive conveyor troughs sieves and vibrating tables The drive medium is clean filtered compressed air or nitrogen In addition the frequency can be infinitely controlled by means of pressure regulators or throttles in the supply line Special Features e No bearings e Frequency infinitely variable by air pressure e Easily and quickly removable e Noise reduced design NQT In these operating instructions the following information and danger symbols are used Notes on important processes on Notes on important processes processes sro apa note on processes to Be eeped alli cbseniec eS Environmental waste disposal DA emirate canger source Waring ofa danger source a dan
4. also the power Operating time The technical performance changes with long operating times wear Dimensions mm Vibrators NVR NVT NQT B C E Es 175 A 175 NVR 49 55 61 182 140 1755 90 l NVT 82 113 84 87 105 240 185 150 83 225 o L NVG 82 113 84 87 105 NQT 93 108 240 230 240 80 l 2 Lo o gt Bracket A 180 240 3 Design and function The vibration is produced by the eccentric to the shaft driven internal rotor and for larger units by the external rotor The compressed air enters at P into the shaft and pushes the movable vane against the inner rotor Through the air channels of the vane the compressed air moves to the pressure side air chamber F of the vane The constant air increases the volume of the air chamber F and displaces the position of the rotor The rotation of the inner rotor changes the shape of the chamber F to finally connect the air with chamber G and the compressed air escapes through the exhaust holes R air chamber F exhaust R air chamber G dj N eA external rotor rst aN y The rotor turns now with the help of the kinetic energy until it reaches the starting position and the two air chambers F and G are again incurred For larger units an additional external rotor is driven by the inner rotor The position of the exhaust holes is observed during installation In this position
5. liquid screw retention agent e g Loctite 270 The tightening torques can be taken from the following table Higher tightening torques may cause fracture of screws or tearing of threads Inadequate screw connections may cause loosening of units by vibration This can cause damage to persons and material Recommended average tightening torques for screws property class 8 8 used on NVG vibrators Screws as delivered not additionally greased or oiled MI Nm The screws M16 for NVG version with base plate can be secured with LOCTITE or similar Tighten the spigot nut of the bracket NVH 1 with 150 Nm tighten the spigot nut of the bracket NVH 4 with 300 Nm and check periodically see Chap 9 Troubleshooting Power drop Air supply line The air resistance increases with the hose length The following recommendations refer to hose lengths of max 5 m up to the next bigger hose cross section up to NVG NVR 61 a length of 10 m is possible For longer supply lines we recommend bigger cross sections lf the vibrators are supplied with a 1 m hose coupling and control cock valve the specification 5 m or 10 m to the supplied coupling is valid Minimum cross sections for valves and hoses Valve Connection G1 2 NW 12 Hoses Inner diameter 16 mm Check whether all hoses valves and fittings are approved for the operating pressure When being used under higher temperatures the permissible pressure m
6. sound level but also the power Technical changes to the equipment may affect the characteristics of the vibrators or even damage the units and cause the rejection of any warranty claims Failures to comply with the operating instructions cause the rejection of any warranty claims Drive medium Clean filter lt 50 um compressed and lubricated air or nitrogen Unfiltered air will cause damage to the vibrators Operating pressure 2 bar to 6 bar Operating pressures must not be exceeded or fallen short of Temperature 10 C to 60 C Operating temperatures must not be exceeded or fall short of For higher temperatures appropriate vanes are available Frequency Max 15 000 min The maximum speed must not be exceeded Higher temperatures and frequencies are only permitted after consultation by application engineers of Netter GmbH 5 Transport and storage Check the packing for possible shipping damage The units are packed ready for installation The type plate is mounted on the vibrator The units are delivered with a socket if the socket is not already part of the shaft If the units are ordered with 1 m hose coupling and cock valve this standard equipment is supplied ready assembled if not specified differently lf the packing is damaged check the contents for completeness and possible damage In case of damage inform the transport agent Compare the scope of supply with the delivery no
7. air supply Ensure the use of ear protection Adjust the desired frequency on the pressure regulator Adjust the mist lubricator if existing 8 Service Maintenance When servicing the unit please observe the safety regulations in chapter 4 Retightening screw connections must be checked and if necessary retightened after 1 hour of operation after initial start up and then at regular intervals normally each month The specified torque must thereby be observed see chapter 6 Before each inspection and service works shut off the compressed air supply and secure it against unintended activation Mist lubricator Water must not enter into the inside With a mist lubricator connected in series make sure that it works as Contamination specified contents diminishing number Further notes can be found in chapter 9 of drops min Top up oil roubleshooting Cleaning The maintenance intervals mainly depend on the purity of the drive All NVT vibrators can be externally ea cleaned with pressure water as long as the exhaust openings are closed 13 9 Troubleshooting Fault Possible cause Remedy No start Air supply Check the pressure at the unit Sufficient pressure Check the valve Wrong position of Turn vibrator or cover see below Exchange of exhaust bores see vane Installation Vane jammed Check the vane see below Exchange of vane missing or incorrectly inserted Too low Hose
8. ay be lower Before applying any pressure check that all pressure connections are secure hose clamps tightened When using compressed air as drive medium it must be clean filtered Unfiltered air leads to excessive wear and complete damage of the vibrator The compressed air supply must be reliably fastened Filter recommended Install the unit Lock the fastening screws Attend the expected operating temperature Assemble maintenance unit valve supply line Have fastening screws been locked Check Specification on hose length and diameter observed Has the unit been secured against falling down 7 Start up Operation Start up of the vibrators can be performed immediately after the correct installation Sound level The frequency can be adjusted or regulated with the pressure regulator on the service unit During the operation the sound level of the vibrators exceeds 85 dB A ear protectors are required Due to their high power the external vibrators NVG NVT and NVR have plates molds etc a sound level higher than 85 dB A especially if they are mounted on A sound insulation of the unit is only useful if plates and formwork panels are also insulated Pressure reduction reduces the sound level but also the power Standard installation Special plans on request lf the supply line is fitted with a 2 2 way cock valve this can be used to regulate the frequency and the centr
9. cross sections Observe minimum cross sections and lengths power see specifications under Installation Check the air pressure Check the supply lines Wear Check the vane in particular also cover and inner rotor Unit runs in resonance Better reinforcement Or choose a unit with a frequency No lower working moment smaller outer rotor increase in speed despite an increase of pressure Power drop Screws loose typical Re tighten the screws especially the nuts on sudden speed NVH brackets reduction Unit soiled Fill approx 1 cm of kerosene into the supply line and run the vibrator for a moment Sound level Frequency range Avoid locations which may rattle Adjust the rattling frequency to a lower sound pressure level 14 Exchange of the Vane The vane is an item which wears out The use of clean and lubricated com pressed air prolongs its lifetime Loosen the housing screws 10 11 12 and press the axle 6 out from the side of the front flange 2 This may be ac complished either hydraulically raise the rim of the housing for this purpose or by clamping the recess A of the housing ina vice and knocking the shaft 6 with a hammer and a brass mandrel The shaft will then drop out of the housing together with the rear flange 3 and the fitting 9 These parts remain together The rotor or the rotors 4 5 will also fall out Now inspect the vane for signs of wear and replace it with a new one if this is necessary The va
10. eu matically controllable for remote control See also F L R units pressure regulators F L R units Filter pressure regulator lubricator or complete units respectively Duty and break cycle electric or pneumatic for interval operation control Brackets for quick relocation of vibrators on formwork contain ers etc Special versions With exhaust air discharge e g for the use in aggres sive environments rotors for other working moments 11 2 Disposal Depending on the material the parts must be disposed of according to official regulations Material specifications All parts of these vibrators are suitable for recycling e Housing Steel or cast steel e Rotor Shaft Cover 5 hardened steel e Bracket NVH weldable cast steel or steel All units can be disposed of through Netter GmbH The current disposal prices are available on request 11 3 Enclosures Enclosure s Further information available on Declaration of incorporation request Leaflet no 14 Vibrators 16
11. ger source 2 Technical data Drive medium Clean filter lt 50 um compressed and lubricated air or nitrogen Unfiltered air will cause damage to the vibrators Operating pressure 2 bar to 6 bar Operating pressures must not be exceeded or fallen short of Temperature 10 C to 60 C Operating temperatures must not be exceeded or fall short of For higher temperatures appropriate vanes are available Frequency Max 15 000 min The maximum speed must not be exceeded Higher temperatures and frequencies are only permitted after consultation by application engineers of Netter GmbH ava NVR NVG2 NVT NVG yP 49 55 61 82 113 frequency IN cmkg Air consumption l min kg 66 70 76 without hose kg a NVT NVG NQT yP 8 87 105 93 108 4 frequency Weight ae ae 20 3 without hose kg a a a ee Weight Cs ee SES NVG with base plate NVT and NQT with carrier handle on top for bracket NVH 4 NVR without carrier handle for bracket NVH 1 Data obtained on 6 bar Sound level During the operation the sound level of the vibrators exceeds 85 dB A ear protectors are required Due to their high power the external vibrators NVG NVT and NVR have a sound level higher than 85 dB A especially if they are mounted on plates molds etc A sound insulation of the unit is only useful if plates and formwork panels are also insulated Pressure reduction reduces the sound level but
12. ifugal force A pressure regulator allows a more exact regulation independent from the original pressure Valve filter and lubricator regulator may also be used for several units The size of these components must then be determined accordingly Start up The vibrators have to be mounted with the air holes in position A or B In position C or D the vibrator will not Start because the rotor is resting on the vane which is shown in Design and Function in the lower figure lf necessary the housing must be rotated If this is not possible e g in case of NVI housings in conjunction with the bracket NVH the cover can be rotated This procedure is described under Exchange of the vane see page 15 12 Coupling with seal and strainer Cock valve 3 2 Way valve OORE t p start up lx Best start up No start up in Pos A B in Pos C D The use of lubricated air significantly increases the lifetime If not lubricated compressed air is used give periodically e g every 1 2 hours 1 cm oil in the supply line Longer intervals are possible but can cause rapid wear Recommended oil quality SAE 10 Oil quality SAE 10 2 3 drops min ATTENTION Las Adjust number of drops while unit is running 33 Only after the adjustment and correct function of the mist lubricator the unit is ready for operation Checklist for commissioning Check all hose connections before opening the compressed
13. ne must be easy to move or otherwise it must be In case of a power drop the reason is normally a worn vane if the above tests do not reveal anything else The vane must be replaced as follows Housing Front flange Rear flange Outer rotor Inner rotor Shaft Vane Fitting key Connecting fitting 10 Housing screw 11 Stop nut 12 Lock washer OCON DOOR WND ground in so that it fits tightly The open channels of the vane must point away from the exhaust bores B Assembly must be performed in reverse order whereby the cover is pressed in or knocked in with a plastic hammer During this procedure observe the correct position of the flanges to each other fitting keys 8 lf necessary start up position the flanges may be turned In this case the front flange 2 must also be loosened The housing screws 10 must all be re tightened after a short test operation Tightening torque for housing screws M8 25Nm M10 51Nm 10 Spare Parts Please provide the following information when ordering spare parts 1 Type of unit 2 Description of spare part 3 Required quantity 11 Appendix 11 1 Accessories The following accessories are available for the vibrators on ink Description a material and Se eee air supply and exhaust option in different fittings qualities and dimensions 3 2 or 2 2 way valves _ for electric pneumatic and manual control Throttle valves for frequency control manually adjustable or pn
14. sign and Function shown in the lower figure If required the cover must be rotated This procedure is described under exchange of the vane on hoppers for emptying on vibration chutes here NVT Best start up in Pos A B The vibrators of the series NVR or NVT are to be fastened to the vibrating mass by means of a separate bracket NVH 1 or NVH 4 These brackets must be welded to the construction to be vibrated STOP In critical installation situations the unit must be secured with clamp and steel rope Installation examples for NVG and NVT on tilting tables etc for concrete compaction here NVT NVH 1 or NVH 4 the vibration transmission is due to the particularly strong connection especially favorable 7 O86 28 sta un Co No start up in Pos C D Mounting notes The types NVG have a base plate which is bolted to the vibrating structure The types NVR and NVT have a cast housing which is clamped in a bracket s NVH 1 or NVH 4 by a spigot nut This brackets in weldable cast steel get to be welded to the vibrating structure This combination vibrator construction gt is particularly force fit Vibrators with the housing design NVR and NVT are quickly removable Then for each position a bracket is Bracket NVH 1 or NVH or 4 required for NVR or NVT As a protection against loosening use self locking screws and nuts self locking lock washers no spring washer or use a
15. te Special transport conditions are not specified The units should be stored in a dry and clean environment Units must be oiled before being returned to the stores put machine oil in air inlet and outlet and operate the vibrator short The storage temperature may be between 40 C and 60 This does not apply for operating temperature compare with chapter 4 SAFETY Permissible Operating Conditions 6 Installation During installation please comply strictly with the safety regulations in chapter 4 and the prevention instructions accident Make sure the compressed air supply is switched off during installation or when working on vibrator and air supply lines Mounting the vibrator The vibrators of series NVG are screwed with the base plate to the vibrating mass Depending on the housing size the NVG is available with a base plate with 2 bores 16 5 mm or 4 bores 17 0 mm These base plates are fastened accordingly with 2 or 4 screws M16 quality 8 8 A on vibration tables for compaction testing and others here NVG The shape of the housing has only a minor influence on the effect With the units NVT which are clamped with a Spigot nut in the welded on bracket Start The vibrators have to be mounted with the air holes in positions A or B In positions C or D the vibrator will not Start because the rotor is resting on the vane which is described in De
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