OPERATION MANUAL & PARTS LIST HFO FREQUENCY CONVERTERS

Transcription

1 OPERATION MANUAL & PARTS LIST HFO FREQUENCY CONVERTERS LIEVERS HOLLAND Groot Mijdrechtstraat RW Postbus AC Mijdrecht (NL) Tel.: 0031 (0) / Fax: 0031 (0) info@lieversholland.nl / Internet:

2 1. PREFACE INTRODUCTION TECHNICAL SPECIFICATIONS SAFETY USE MAINTENANCE TROUBLESHOOTING, REPAIRS DISMANTLING, DISPOSAL PART LISTS DECLARATION OF CONFORMITY Lievers Holland, NL All rights are reserved. Reprints, copies, adaptations for new editions and publications in any form or through any media, including abstract forms are not permitted unless written permissions is first obtained from Lievers Holland. Lievers Holland may not be held responsible for any guarantees or liabilities for the contents of this publication and points to, in this case, all implied securities for suitability of merchantability or any other purposes. Lievers Holland further retains the right to revise this publication and to alter the contents over certain periods of time, without the obligation to report such alterations and changes first. 2/24 Operation manual HFO, revision 1:

3 1. Preface This manual has been written to help you operate and maintain the high frequency converter HFO safely. This manual is intended for dealers and operators and contains useful instructions for use, maintenance and repair. These instructions need to be respected and followed. Guarantee provisions All damage to parts of the poker vibrator, occurring within 12 months after date of purchase as a consequence of material, production or construction defects, will be replaced by the manufacturer as soon as possible. The manufacturer declines all responsibility for unsafe situations, accidents and damage caused by: Incompetent use. Ignoring safety and using instructions as described on the machine or the instruction manual. Incompetent or incorrect maintenance, for instance, cleaning with a high pressure cleaner or by a water jet under high pressure. Connecting the machine to the wrong voltage. Storing the machine in a damp place. Assembling or dismantling of the poker vibrator by unqualified personnel (employees who are unfamiliar with the content of this instruction manual). Other use than the prescribed use. Alternations of the machine carried out by other than manufacturer. This also includes assembling of non-original parts. Guarantee certificate HFO Nr.: Date of purchase: Fig. 1: Rating plate on housing of switch 3/24 Operation manual HFO, revision 1:

4 2. Introduction What is a frequency converter? A frequency converter is an apparatus which transforms the mains voltage to a safety voltage of < 50VAC-3 phase and, at the same time, converts the mains frequency of 50 Hz. to 200 Hz. This safety voltage of 42-48VAC- 3 phase, 200Hz. is the supply voltage needed for the motor in head vibrator to rotate and vibrate at p/min. Operation The converter is connected to a mains voltage of 400VAC- 3 phase or, depending on the type of converter, to 110/230 VAC- 1 phase. The electric motor inside the converter drives a generator which converts the mains voltage to a secondary safety voltage of < 50 VAC- 3 phase and, at the same time converts the mains frequency from 50 to 200Hz. Fig. 2: Overview important components 1. Carrying frame 2. Supply-cable 3. Thermical overload switch 4. CEE-socket 4/24 Operation manual HFO, revision 1:

5 3. Technische specifications Technical data TYPE POWER- PRIMARY PRIMARY SECONDARY SECONDARY NO. OF WEIGHT output (KVA) (V/Phase/Hz.) amps. (V/Hz.**) amps. outlet ( kg) HFO 0.7/ /1/ / HFO 1.2/ /1/ / HFO 1.2/ /3/ / HFO 1.8/230* /1/ / HFO 1.8/400* /3/ / HFO 2.5/230* /1/ / HFO 2.5/400* /3/ / HFO 3.0/400* /3/ / HFO 4.0/400* /3/ / HFO 6.0/400* /3/ / *Optional: wheelbarrow Idem, with cabledrums Idem, with cabledrums and sliprings Sealing Insulation Execution Dimensions : IP 54, splashproof : I : portable or on a wheelbarrow : depending on the execution 5/24 Operation manual HFO, revision 1:

6 4. Safety Explanation of the used safety symbols 1. Read the operating manual before using the machine. 2. Safety glasses, safety helmet and ear protection compulsory. 3. Gloves compulsory 4. Safety shoes with extra protection compulsory. 5. Before opening the motor housing remove the plug. 6. Dangerous electrical voltage. 7. Look out and be careful. Figure 3: safety symbols ENSURE THAT ALL SYMBOLS ON THE CONVERTER CAN ALWAYS BE CLEARLY READ. General safety aspects All Lievers equipment have been tested in accordance with the strict international safety standards. This section contains general advice and apply to several machines from the LIEVERS range. Ensure that you are qualified (familiar with the contents of this manual), to operate and carry out light maintenance-work to the machine when you are operating the machine for the first time. Wear safety shoes with extra protection (steel caps and anti-slip soles) Wear a safety helmet, ear protection, safety glasses and working gloves, which do not conduct electricity and protective clothing. Ensure, that all symbols on the machine, can always be clearly read. Do not leave any tools or parts lying around on the work floor, as this can cause accidents. Watch where you are going, the ground can be slippery. Be careful not to injure yourself on objects, such as scaffolding and reinforcement materials, which can be found directly or indirectly in the working area. Be careful when lifting and carrying the converter. Do not bend forwards when picking up the apparatus, but bend your knees. Ensure that the working area is within your reach, so that you do not have to bend forward. When cleaning the machine, ensure that no water or cleaning detergents get into the motorhousing. When the machine is not being used for longer periods of time, then it must be stored in a dry and clean area. 6/24 Operation manual HFO, revision 1:

7 Do not only pay attention to your own safety, but also to that of your colleagues. Regular maintenance of the machine promotes safe operation. The following safety-aspects specifically apply to those Lievers products which are equipped with an electrical drive unit. Place the wires between the electrical source and the work place in such a way, that they cannot be damaged and your colleagues cannot trip over them. Do not use the machine in an explosion endangered area. Check that the electrical source complies with the local valid regulations. Use earthed extension leads, when it is necessary to use extension leads. Use an electrical source which is provided with an earth leakage switch or attach a safety transformer between the electrical mains and the machine. If you want to connect a machine to a mains voltage of 400VAC, 3 phase, ensure that the supply cable has an earthlead and that the plug complies to the valid regulations. Ensure that the wall socket and possible connections between the extension leads are protected against dampness. Do not pull the plug out of the wall socket or extension lead by its lead. Regularly check the connections of the supply-cable to the switch. Check the feeder cable s outercasing and if in use extension lead s outercasing before you connect the machine to the electrical mains. The outercasing may not be damaged. Replace the cable if you cannot read the marks on the outercasing anymore. Check the machine s cable-connections before you connect the machine to the electrical mains. The cables must be properly connected. Switch off the machine, when the electrical power cuts off. This prevents the machine from starting suddenly when the electrical power comes on again. Disconnect the electrical supply to the machine, before you start to clean or maintain the machine. Ensure that the ventilation slots of the machine are free from dirt and moisture. 7/24 Operation manual HFO, revision 1:

8 The following safety-aspects specifically apply to Lievers products equipped with a petrol-engine. Do not use the converter with petrol-engine indoors! Never inhale exhaust gasses, they can damage your health and that of your colleagues. To avoid getting an electric shock, do not touch the high-tension cable or spark plug cap while the engine is running. Check for fuel leaks before running the machine. Do wear working-gloves, safety glasses and protecting clothing during refueling. Make sure that there is sufficient ventilation during refueling. Refueling of fuel is only allowed after the engine has been cooled off sufficiently. Refueling of fuel, while the engine is hot, might lead to a very dangerous situation. It is strictly forbidden to refuel : * in the direct vicinity of open fire or other flammable materials, * while smoking cigarettes etc. * in explosion endangered spaces. Specific safety instructions (HFO converters) This section contains safety instructions which specifically apply to the frequency converter type HFO. Do read the safety instruction carefully!! It is very important that you follow these instructions carefully. Regular servicing is a must, as it promotes safety while operating the frequency converter. First switch on the converter before you switch on the poker-vibrator. Make sure that the supplied capacity of the converter is enough to drive the pokers you want to connect. It is not allowed to clean the converter with a high pressure cleaner. Please read chapter 6, maintenance and repair carefully. Do not change the adjustment of the thermical overload switch. When the thermical overload switch comes into operation, it clearly indicates an electrical failure. Do not carry on the operation, before you have tracked down and solved the cause for this failure. Before you connect the converter to the mains voltage, ensure that the mains voltage corresponds with the technical specifications of the rating plate. Ensure that you are familiar with the current regulations for plug and cable connections. Put the converter on a firm foundation (i.e. a wooden board) to prevent it from sinking into soft ground or freshly poured concrete. During movement of the converter by means of a crane, it is not allowed to attach the hoisting rope to the handle and the carrying frame of the converter. Remember that any kind of manipulation and repair to the converter are strictly reserved to authorized personnel only. Tip: ask the manufacturer for advise, if you have any questions about these instructions. Lievers Holland, Service Department Telephone : Telefax : /24 Operation manual HFO, revision 1:

9 5. Use This chapter describes the use of the frequency convertor type HFO. Tip: For the location and description of the converter s parts, which are mentioned in the text, we refer to the illustration 2 on page 4. Operation and application of the frequency converter. Switching on the frequency converter. Fig. 4: ON and OFF position of the converter 1. Check the controls before switching on the converter. 2. Ensure that the mains voltage is sufficiently fused. 3. Ensure that the high frequency poker-vibrator is in the OFF position, before you switch on the converter. 4. Place the converter outside the working area of where you are going to compact concrete. (Not into the freshly poured concrete). 5. Switch on the connected poker-vibrator(s). Read the operation instructions of the Lievers poker-vibrators type LHF & HS. 6. First switch off the poker-vibrator(s), before you switch off the converter. 7. Pull the converter s plug out of the wall socket and wrap the supply cable round the converter. 8. After use, clean the converter according to the instructions described in chapter 6 of this manual. Place the converter on a dry and stable surface. Thermical overload switch. All Lievers converters are equipped with a thermical overload switch. ln case of overloading or electrical failure, the switch automatically cuts off the electrical supply. 9/24 Operation manual HFO, revision 1:

10 In case the thermical overload switch comes into operation proceed as follows: 1. Switch off the connected poker-vibrator(s). 2. Allow the switch to cool off for approx. 3 minutes. 3. Check the electrical supply to the converter or, check the poker-vibrator(s) for faults. 4. Switch on the converter again by putting the switch in the ON position. 5. Proceed with the compaction of the concrete. Warning: When the thermical overload switch cuts off the electrical supply again, it may indicate an electrical failure to the converter. Stop the operations and have your converter inspected as soon as possible. 1. Maintenance Although the converter has a few moving parts, regular maintenance promotes a long and trouble-free life. WARNING: DO NOT CLEAN THE CONVERTER WITH A HIGH PRESSURE CLEANER. DISCONNECT THE ELECTRICAL SUPPLY TO THE CONVERTER BEFORE YOU CARRY OUT ANY MAINTENANCE ACTIVITIES TO THE CONVERTER. Cleaning and servicing of the converter. During concrete compaction the converter, switch and supply cable will become dirty. Periodical maintenance is vital to the safe and efficient operation of the converter. It is therefore highly recommended to clean the converter daily with water and a cleaning detergent, that does not affect the converter s material. In order to achieve a maximum cooling effect, the ventilation slots of the converter must stay free from dirt and grease. Check them at the end of each working day. lf necessary clean them with a brush or a damp cloth. If the converter is not used for a long period of time, store it in a clean, dry and dustfree place. Tip: ln case of failure or break down of the converter, we advise you to send the machine to an authorized Lievers/service-station. WARNING: WE STRONGLY ADVISE YOU NOT TO CARRY OUT REPAIRS TO THE CONVERTER BY YOURSELF, WITHOUT BEING INSTRUCTED BY THE MANUFACTURER OR DEALER (READ GUARANTEE-PROVISIONS). 10/24 Operation manual HFO, revision 1:

11 7.Troubleshooting, repairs The table below shows the most occurring problems, causes and solutions: PROBLEM CAUSE SOLUTION The connected and activated convertor does not get into the required number of revolutions or does not start. The convertor is overloaded due to insufficient current supply. Ensure that the supply cable is connected to the required voltage. Check the plug connections for faults. Check the length of the extension cable - if in use -. Use an extension cable of max. 25m with a cross section of 3x2.5mm2 for convertors which are connected to 110/230VAC/I phase, or use an extension cable with a cross section of 4x2.5mm2 for convertors connected to 400VAC 3 phase. The convertor overheats and trips out. The thermical overload switch of the convertor trips out. The activated convertor does not start. Insufficient cooling of the convertor due to blocked ventilation-slots. Breakdown of the convertor, or a wrong type of convertor (capacity) Too many pokers have been connected to the convertor. A break in the supply cable, or the main fuse tripped out. Clean the convertor s ventilation slots, according to chapter 4 of this manual. Check the current supply to the convertor (2-phase run).ensure that the convertor s (capacity) power output is sufficient for the connected pokervibrator(s). Check the supply cable and replace it if necessary. Reset or replace the main fuse. Table 2: the most occurring problems, causes and solutions. Careful!:Faults that frequently occur are: - A break in the supply cable. - Incorrect plug connections. - Insufficient maintenance. - Wrong type of convertor or poker-vibrator. Unsuited to do the job. Tip: Please contact Bouwmachinefabriek Lievers B.V. if problems occur which are not mentioned in the list, or if a mentioned problem is not solved by the solutions in the list. 11/24 Operation manual HFO, revision 1:

12 Repairs It is not strictly necessary to keep spare parts of the HFO converter in stock. If you prefer to have parts in stock, please ask your supplier or dealer for advice. TIP: WHEN ORDERING PARTS, FILL IN THE ORDER FORM ACCURATELY. LIEVERS B.V. DECLINES ALL RESPONSIBILITY FOR THE SUPPLY OF INCORRECT SPARES DUE TO INCOMPLETE OR UNCLEAR REQUESTS. When ordering parts please state the following information: Type of machine. Year of construction. Order number plus description of the part. The required quantity. The dispatch address and dispatch mode. Contact details Lievers Holland: PO Box AC Mijdrecht Tel: +31 (0) Fax: +31 (0) Internet: 8.Demontage, verwijderen National and local regulations concerning dismantling and disposal of materials need to be obeyed. According to our knowledge, HFO converters do not contain material which is a danger to the environment. 12/24 Operation manual HFO, revision 1:

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14 9. Part lists Fig. 5: Exploded view HFO 0.7 kva 230V & 1.2 kva 230 & 400V 14/24 Operation manual HFO, revision 1:

15 INDEX ARTICLE QUANTITY DESCRIPTION NUMBER Bearingshield generatorside Bearing A 4 Thread end 0.7 KVA 230V. 1 Ph B 4,, 1.2 KVA 230V. 1 Ph. &1.2 KVA 400V. 3 Ph Capicitor 18uF ANIE 1 Rotor 0.7 KVA 230V. 1 Ph BNIE 1,, 1.2 KVA 230V. 1 Ph CNIE 1,, 1.2 KVA 400V. 3 Ph A 1 Motorhousing+stators 0.7 KVA 230V. 1 Ph B 1,,,, 1.2 KVA 230V. 1 Ph C 1,,,, 1.2 KVA 400V. 3 Ph Bearingshield motorside Ventilator NIE 1 Ventilatorcap Rubber gasket NIE 1 Switchbox 1.2 KVA 400V. 3 Ph Therm.switch 1.2 KVA 400V. 3 Ph. 2.8 amp NIE 2 Support Therm.switch 0.7 KVA 230V. 1 Ph. 6 amp. 26A Protection cap for switch 230V Therm.switch 1.2 KVA 230V. 1 Ph. 8 amp. 27B NIE 1 Protection cap for switch 400V Cable sleeve Cable clamp Supply cable 3x2.5mm2. 110/230V. execution ,,,, 4x2.5mm2 400V. execution CEE-socket 42V Plug (earthed) Spring washer 51 x 42 mm Screw for cable clamp M5x25mm Carrying handle NIE 1 Connection terminal Capicitor 20 uf. 450V Switchbox 0.7 & 1.2 KVA 110/230V. 1 Ph. Table 3: Parts HFO 0.7 kva 230V & 1.2 kva 230 & 400V 15/24 Operation manual HFO, revision 1:

16 Fig 6: Exploded view HFO 1.8 & 2.5 kva 230V 16/24 Operation manual HFO, revision 1:

17 INDEX ARTICLE QUANTITY DESCRIPTION NUMBER /3 CEE-socket 42VAC. 200Hz /3 CEE-socket 115/250V. 200Hz Cable sleeve Plug (earthed) Cover for switchbox Screw M5x16mm NIE 1 Switchbox Carrying frame Bearing Spring washer Screw M5x25mm Supply-cable 3x2.5mm Ventilator Capicitor 1 Ph. 35uF Capicitor 1 Ph. 50uF NIE 1 Ventilatorcap NIE 1 Bearingshield ventilatorside NIE 1 Bearingshield generatorside Cable clamp B 4 Threadend 1.8 KVA Threadend 2.5 KVA NIE 1 Motorhousing + stator 1.8 KVA NIE 1 Motorhousing + stator 2.5 KVA NIE 1 Rotor 1.8 KVA NIE 1 Rotor 2.5 KVA Gasket switchbox Support Rubber seal Therm. switch 1.8 KVA 230V. 48A Protection cap for 1.8 & 2.5 KVA ,,,, 2.5KVA 230V Table 4: Parts HFO 1.8 & 2.5 kva, 1-phase 230V 17/24 Operation manual HFO, revision 1:

18 Fig. 7: Exploded view HFO 1.8 & 2.5 kva 400V 18/24 Operation manual HFO, revision 1:

19 INDEX ARTICLE NUMBER QUANTITY DESCRIPTION /3 CEE-socket 42VAC. 200Hz /3 CEE-socket 115/250V. 200Hz Cable sleeve Rubber seal Cover for switchbox Screw M5x16mm NIE 1 Switchbox Carrying frame Bearing Spring washer Screw M5x25mm Supply-cable 4x2.5mm Ventilator NIE 1 Ventilatorcap NIE 1 Bearingshield ventilatorside NIE 1 Bearingshield generatorside Cable clamp Threadend 1.8 KVA B 4 Threadend 2.5 KVA NIE 1 Motorhousing + stator 1.8 KVA NIE 1 Motorhousing + stator 2.5 KVA NIE 1 Rotor 1.8 KVA NIE 1 Rotor 2.5 KVA Gasket switchbox Support 1.8 KVA Support 2.5 KVA NIE 1 Therm. switch 1.8 KVA 400V N 1 Rubber seal for switch NIE 1 Therm. switch 2.5KVA 400V 49A NIE 1 Protection cap for 1.8 & 2.5 KVA Table 5: Parts HFO 1.8 & 2.5 kva, 400V 19/24 Operation manual HFO, revision 1:

20 Fig. 8: Exploded view HFO 3.0 & 4.0 kva 400V 20/24 Operation manual HFO, revision 1:

21 INDEX ARTICLE NUMBER QUANTITY DESCRIPTION Thermical Relais 11.5 Amp /3 CEE-socket 42VAC. 200Hz /3 CEE-socket 115/250V. 200Hz NIE 1 Switchbox 3.0 & 4.0 KVA 400V Cover for switchbox Screw M5x16mm Rubber seal Gasket switchbox Cable clamp Screw Pushbutton for switch Protectioncap NIE 1 Motorhousing + stator 3.0 KVA NIE 1 Motorhousing + stator 4.0 KVA NIE 1 Bearingshield generatorside3.0 & 4.0 KVA Bearing NIE 1 Rotor 3.0 KVA NIE 1 Rotor 4.0 KVA Spring washer Bearingshield ventilatorside 3.0 KVA NIE 1 Ventilator NIE 1 Ventilatorcap Thread end 3.0 KVA Thread end 4.0 KVA Support 3.0 & 4.0 KVA Carrying sledge 3.0 KVA NIE 1 Carrying sledge 4.0 KVA NIE 1 Connection Rubber sleeve Supply-cable 4x2.5mm2 Table 6: Parts HFO 3.0 & 4.0 kva, 400V 21/24 Operation manual HFO, revision 1:

22 Fig. 9: Exploded view HFO 6.0 kva 400V 22/24 Operation manual HFO, revision 1:

23 INDEX ARTICLE QUANTITY DESCRIPTION NUMBER Cover for switchbox Connection terminal Plastic sleeve with packingbox PG 13, Supply-cable 4x2.5mm Thermical Relais 16 Amp NIE 1 Ventilatorcap Pushbutton for switch Protectioncap Spring washer Switchbox NIE 1 Ventilator NIE 1 Bearingshield ventilatorside /4 CEE-socket 42VAC. 200Hz Cable clamp Motorhousing + stator Support NIE 1 Bearingshield generatorside Bearing Rotor Threadend Table 7: Parts HFO 6.0 kva, 400V 23/24 Operation manual HFO, revision 1:

24 10. Declaration of conformity EC DECLARATION OF CONFORMITY EC-declaration of agreement for machinery (Directive 2006/42/EC, Annexe II, under A) Supplier: Bouwmachinefabriek Lievers B.V. Address: Groot Mijdrechtstraat 68, 3641 RW Mijdrecht Hereby declares that The high frequency converters HFO: 1) comply with the regulations in the machine directive (2006/42/EC), EMC directive (2004/108/EC), directive (2006/95/EC) and directive (2002/49/EC) 2) comply with the following harmonised standards: EN Mijdrecht, July 1st, 2010 Supplier: Address: Bouwmachinefabriek Lievers B.V. Groot Mijdrechtstraat 68, 3641 RW Mijdrecht Name: C.M. de Wit Position: Managing Director 24/24 Operation manual HFO, revision 1: