Electric External Vibrators Normal & High frequency
Contents Contents Introduction........................................................................ 5 About the.......................................... 5 Safety instructions................................................................. 6 Safety signal words.............................................................. 6 Work area....................................................................... 6 Electrical safety................................................................. 6 Personal safety.................................................................. 7 Personal protective equipment................................................... 7 Drugs, alcohol or medication.................................................... 7 Operating, precautions........................................................... 8 Maintenance, precautions........................................................ 9 Storage......................................................................... 9 Overview......................................................................... 10 Design and function............................................................ 10 Main parts..................................................................... 10 Labels......................................................................... 10 Data plate.................................................................... 10 Operation......................................................................... 10 Preparations before vibrating.................................................... 10 Testing...................................................................... 10 Vibrating..................................................................... 11 Overload.................................................................. 11 Procedure in event of excessive load......................................... 11 When taking a break.......................................................... 11 Installation........................................................................ 11 Transport...................................................................... 11 Locating and fixing............................................................. 11 Bolt mounting.................................................................. 12 Bracket mounting.............................................................. 12 Control of vibrator.............................................................. 12 Electrical supply................................................................ 1 Normal frequency,000 r.p.m.................................................... 1 High frequency 6,000 r.p.m...................................................... 14 Maintenance...................................................................... 15 Every 10 hours of operation (daily)............................................... 15 Electrical connections......................................................... 15 Every 75 hours of operation (or every second week).............................. 16 Lubrication................................................................... 16 Tigthening tourqe............................................................. 16 Every 100 hours of operation (or monthly)........................................ 16 Replacement of the bearings................................................... 16 Storage........................................................................... 17 Disposal.......................................................................... 17 Troubleshooting................................................................... 18 Technical data..................................................................... 19 Normal frequency,000 r.p.m. ( Hz)........................................... 19 High frequency 6,000 r.p.m. ( Hz)............................................. 19
Contents Normal frequency,0 r.p.m. ( Hz)........................................... 19 High frequency 5,400 r.p.m. ( Hz)............................................. 19 Electrical supply................................................................ 20 Noise declaration statement..................................................... 20 Noise data..................................................................... 20 Dimensions.................................................................... 21 EC Declaration of Conformity...................................................... 22 EC Declaration of Conformity................................................... 22 4
Introduction Thank you for choosing a product from Atlas Copco. Since 187, we have been committed to finding new and better ways of fulfilling our customers' needs. Through the years, we have developed innovative and ergonomic product designs that have helped customers improve and rationalize their daily work. Atlas Copco has a strong global sales and service network, consisting of customer centers and distributors worldwide. Our experts are highly trained professionals with extensive product knowledge and application experience. In all corners of the world, we can offer product support and expertise to ensure that our customers can work at maximum efficiency at all times. For more information please visit: www.atlascopco.com Construction Tools PC AB Box 70 91 27 Kalmar Sweden About the Safety and operating instructions The aim of the instructions is to provide you with knowledge of how to use the machine in an efficient, safe way. The instructions also give you advice and tell you how to perform regular maintenance on the machine. Before using the machine for the first time you must read these instructions carefully and understand all of them. 5
Safety instructions To reduce the risk of serious injury or death to yourself or others, read and understand the Safety and operating instruction before installing, operating, repairing, maintaining, or changing accessories on the machine. Post this Safety and operating instruction at work locations, provide copies to employees, and make sure that everyone reads the Safety and operating instruction before operating or servicing the machine. For professional use only. In addition, the operator or the operator's employer must assess the specific risks that may be present as a result of each use of the machine. Save all warnings and instructions for future reference. Safety signal words The safety signal words Danger, Warning and Caution have the following meanings: DANGER WARNING CAUTION Work area Indicates a hazardous situation which, if not avoided, will result in death or serious injury. Indicates a hazardous situation which, if not avoided, could result in death or serious injury. Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. DANGER Explosion hazard If a warm machine comes into contact with explosives, an explosion could occur. During operating with certain materials, sparks and ignition can occur. Explosions will lead to severe injuries or death. Never operate the machine in any explosive environment. Never use the machine near flammable materials, fumes or dust. Make sure that there are no undetected sources of gas or explosives. WARNING Secure the working area Cluttered benches and insufficient lighting can cause personal accidents and result in serious injuries. Keep the working area clean. Maintain adequate lighting in the working area. Only qualified and trained persons may operate or maintain the machine. They must be physically able to handle the bulk, weight, and power of the machine. Always use your common sense and good judgement. Keep bystanders, children, and visitors away while operating the machine. Distractions may cause loss of control. Electrical safety DANGER Electrical hazard There is a risk of electrical shocks from electrically powered machines which can lead to serious injuries or death. Avoid body contact with earthed (grounded) surfaces. Make sure that there are no concealed wires or other sources of electricity in the working area. Always check that the mains voltage corresponds with that stated on the data plate on the machine. WARNING Electrical safety There is a risk of electrical shock if the electrical cable is not treated correctly, if the machine is damaged or modified. This can lead to serious injuries or death. The electrical plug on the machine must match the socket. Never modify the electrical plug to match the socket. Do not use adapter plugs with earthed (grounded) machines. Unmodified plugs and matching sockets will reduce the risk of electrical shock. Never move the machine by dragging the electrical cable. Disconnect the cable only by pulling the plug, never pull the electrical cable. Make sure the electrical cable is not pinched in doors, fences or similar. Check that the electrical cable and cable plug are intact and in good condition. Never connect a damaged electrical cable to the machine. Never touch the electrical cable if it becomes damaged during the work. Disconnect the electrical cable plug from the socket. Always make sure that the electrical cable is kept away from water, oil and sharp edges. 6
Do not expose the power tool to rain or wet conditions. If water enters the machine, there is an increased risk of electrical shock. Use a residual current device (RCD) protected supply, if the machine must be operated in a damp location. The use of an RCD reduces the risk of electrical shock. Personal safety Personal protective equipment Always use approved protective equipment. Operators and all other persons in the working area must wear protective equipment, including at a minimum: Protective helmet Hearing protection Impact resistant eye protection with side protection Respiratory protection when appropriate Protective gloves Proper protective boots Appropriate work overall or similar clothing (not loosefitting) that covers your arms and legs. Drugs, alcohol or medication WARNING Drugs, alcohol or medication Drugs, alcohol or medication may impair your judgment and powers of concentration. Poor reactions and incorrect assessments can lead to severe accidents or death. Never use the machine when you are tired or under the influence of drugs, alcohol or medication. No person who is under the influence of drugs, alcohol or medication may operate the machine. WARNING Involuntary start Involuntary start of the machine may cause injury. Keep your hands away from the start and stop device until you are ready to start the machine. Learn how the machine is switched off in the event of an emergency. WARNING Slipping, tripping and falling hazards There is a risk of slipping or tripping or falling, for example tripping on the hoses or on other objects. Slipping or tripping or falling can cause injury. To reduce this risk: Always make sure that no hose or other object is in your way or in any other person's way. Always make sure you are in a stable position with your feet as far apart as your shoulders width and keeping a balanced body weight. WARNING Dust and fume hazard Dusts and/or fumes generated or dispersed when using the machine may cause serious and permanent respiratory disease, illness, or other bodily injury (for example, silicosis or other irreversible lung disease that can be fatal, cancer, birth defects, and/or skin inflammation). Some dusts and fumes created by compaction work contain substances known to the State of California and other authorities to cause respiratory disease, cancer, birth defects, or other reproductive harm. Some examples of such substances are: Crystalline silica, cement, and other masonry products. Arsenic and chromium from chemicallytreated rubber. Lead from leadbased paints. Dust and fumes in the air can be invisible to the naked eye, so do not rely on eye sight to determine if there is dust or fumes are the air. To reduce the risk of exposure to dust and fumes, do all of the following: Perform sitespecific risk assessment. The risk assessment must include dust and fumes created by the use of the machine and the potential for disturbing existing dust. Use proper engineering controls to minimize the amount of dust and fumes in the air and to minimize buildup on equipment, surfaces, clothing, and body parts. Examples of controls include: exhaust ventilation and dust collection systems, water sprays, and wet drilling. Control dusts and fumes at the source where possible. Make sure that controls are properly installed, maintained and correctly used. Wear, maintain and correctly use respiratory protection as instructed by your employer and as required by occupational health and safety regulations. The respiratory protection must be effective for the type of substance at issue (and if applicable, approved by relevant governmental authority). 7
Work in a well ventilated area. If the machine has an exhaust, direct the exhaust so as to reduce disturbance of dust in a dust filled environment. Operate and maintain the machine as recommended in the operating and safety instructions Wear washable or disposable protective clothes at the worksite, and shower and change into clean clothes before leaving the worksite to reduce exposure of dust and fumes to yourself, other persons, cars, homes, and other areas. Avoid eating, drinking, and using tobacco products in areas where there is dust or fumes. Wash your hands and face thoroughly as soon as possible upon leaving the exposure area, and always before eating, drinking, using tobacco products, or making contact with other persons. Comply with all applicable laws and regulations, including occupational health and safety regulations. Participate in air monitoring, medical examination programs, and health and safety training programs provided by your employer or trade organizations and in accordance with occupational health and safety regulations and recommendations. Consult with physicians experienced in relevant occupational medicine. Work with your employer and trade organization to reduce dust and fume exposure at the worksite and to reduce the risks. Effective health and safety programs, policies and procedures for protecting workers and others against harmful exposure to dust and fumes must be established and implemented based on advice from health and safety experts. Consult with experts. WARNING Broken power switch The power switch does not control the machine. A broken power switch is dangerous and must be repaired. Do not use the machine if the power switch is broken and cannot be controlled. Maintain the power switch. WARNING Projectiles Failure of the work piece, of accessories, or even of the machine itself may generate high velocity projectiles. During operating, splinters or other particles from the compacted material may become projectiles and cause personal injury by striking the operator or other persons. To reduce these risk: Use approved personal protective equipment and safety helmet, including impact resistant eye protection with side protection. Make sure that no unauthorised persons trespass into the working zone. Keep the workplace free from foreign objects. WARNING Unexpected movements The machine is exposed to heavy strains during operation. If the machine breaks or gets stuck, there may be sudden and unexpected movement that can cause injuries. Always inspect the machine prior to use. Never use the machine if you suspect that it is damaged. Make sure that the handle is clean and free of grease and oil. Keep your feet away from the machine. Never sit on the machine. Never strike or abuse the machine. Pay attention and look at what you are doing. Operating, precautions WARNING Incorrect usage An incorrect use of the machine, accessories, and insertion tools/ cutting blades can result in serious injuries or a hazardous situation. Use the machine, accessories and tools in accordance with the safety instructions. Use the machine for what it is designed for, and in the way it is intended. Use the correct machine for the work that is going to be performed. Do not force the machine while operating. Take the working conditions into account. 8
WARNING Vibration hazards Normal and proper use of the machine exposes the operator to vibration. Regular and frequent exposure to vibration may cause, contribute to, or aggravate injury or disorders to the operator s fingers, hands, wrists, arms, shoulders and/or nerves and blood supply or other body parts, including debilitating and/or permanent injuries or disorders that may develop gradually over periods of weeks, months, or years. Such injuries or disorders may include damage to the blood circulatory system, damage to the nervous system, damage to joints, and possibly damage to other body structures. If numbness, persistent recurring discomfort, burning sensation, stiffness, throbbing, tingling, pain, clumsiness, weakened grip, whitening of the skin, or other symptoms occur at any time, when operating the machine or when not operating the machine, stop operating the machine, tell your employer and seek medical attention. Continued use of the machine after the occurrence of any such symptom may increase the risk of symptoms becoming more severe and/or permanent. Operate and maintain the machine as recommended in these instructions, to prevent an unnecessary increase in vibration. The following may help to reduce exposure to vibration for the operator: If the machine has vibration absorbing handles, keep them in a central position, avoid pressing the handles into the end stops. When the percussion mechanism is activated, the only body contact with the machine you must have are your hands on the handle or handles. Avoid any other contact, for example supporting any part of the body against the machine or leaning onto the machine trying to increase the feed force. Make sure that the machine is wellmaintained and not worn out. Immediately stop working if the machine suddenly starts to vibrate strongly. Before resuming the work, find and remove the cause of the increased vibrations. Participate in health surveillance or monitoring, medical exams and training programs offered by your employer and when required by law. When working in cold conditions wear warm clothing and keep hands warm and dry. See the Noise and vibration declaration statement for the machine, including the declared vibration values. This information can be found at the end of these. WARNING Noise hazard High noise levels can cause permanent and disabling hearing loss and other problems such as tinnitus (ringing, buzzing, whistling, or humming in the ears). To reduce risks and prevent an unnecessary increase in noise levels: Risk assessment of these hazards and implementation of appropriate controls is essential. Operate and maintain the machine as recommended in these instructions. If the machine has a silencer, check that it is in place and in good working condition. Always use hearing protection. WARNING Accessory hazards Accidental engagement of accessories during maintenance or installation can cause serious injuries, when the power source is connected. Never inspect, clean, install, or remove accessories while the power source is connected. Maintenance, precautions WARNING Machine modification Any machine modification may result in bodily injuries to yourself or others. Never modify the machine. Modified machines are not covered by warranty or product liability. Always use original parts and accessories approved by Atlas Copco. Change damaged parts immediately. Replace worn components in good time. WARNING Damaged machine parts Lack of maintenance will result in damaged or worn parts that can cause accidents. Check the moving parts for misalignment or binding. Check the machine for broken or, in other ways, damaged parts. Damaged or worn parts can effect the operation of the machine. Storage Keep the machine in a safe place, out of the reach of children and locked up. 9
Overview To reduce the risk of serious injury or death to yourself or others, read the Safety instructions section found on the previous pages of this manual before operating the machine. Design and function ER vibrators are designed to vibrate concrete from the outside of forms. They are equipped with a quick release bracket. This allows them to be moved from one form to another during the concrete curing time. The ER vibrators have a dustproof three phase electronic induction motor that is designed with an eccentrics mass located at the end of the shaft. Depending on the type, the vibrator can be operated either directly from the main power supply or through a frequency converter. Main parts K G. Bearing cover H. Eccentric I. Plug J. Gland K. Cover Labels The machine is fitted with labels containing important information about personal safety and machine maintenance. The labels must be in such condition that they are easy to read. New labels can be ordered from the spare parts list. Data plate A B C Type XXXXX Serial No. XXXXXX XXXXV XXXXV 1 XXXXmin Construction Tools PC AB XXA XXA IPXX XXHz XX W Made in XXXXXXX D E I J Electrical drive unit A. Machine type. B. Product identification number. C. Technical characteristics of the machine. C B A D. The warning symbol associated with the symbol of a book means that the user must read the Safety instructions before using the machine for the first time. F E E. The CE symbol means that the machine is ECapproved. See section EC Declaration of Conformity which is delivered with the machine for more information. H G Operation D A. Casing B. Stator C. Rotor D. End cover E. Bearing bracket F. Bearing Preparations before vibrating Testing After the vibrator has been mounted, it has to be tested before normal operation. 10
1. First of all, check that the vibrator is properly connected to the correct voltage. 2. Use an ampere meter to check that the current does not exceed the value specified on the vibrator data plate (see section "Control of vibrator"). If the current exceeds the specified value, abort the test and find out what causes the overload. See section "Overload" Vibrating Overload If the vibrator has been subjected to extreme cold temperature before start, the current during the first 56 minutes may exceed the stated value. This is normal under these conditions. The higher current is caused by a higher friction of the grease at low temperatures. The current decrease is proportional to the increase of the vibrator temperature. In some situations the reduction of the centrifugal force is unavoidable in order to warm up the grease to operating temperature. This process prevents the motor protection from continuously interrupt the power supply and also the risk of damage due to excess current. When the current reaches an acceptable and steady value, reset the centrifugal force to the previous value. If several vibrators are working on the same structure, interactions between vibrators themselves may occur in such a way that the rated current is exceeded not only during startup but also during operation. If the overload becomes so high that the motor protector interrupts the supply, the fault has to be found and corrected. Procedure in event of excessive load In case of a permanent excessive load, the following matters must be investigated: 1. Check that the vibrator has not have loosened from the mounts. 2. Check that the vibrator mounts meet the specified requirements stated in the section "Installation".. Check that the centrifugal force not is adjusted at a too high value. When taking a break During all breaks you must place the machine in such a way that there is no risk for it to be unintentionally started. Make sure to place the machine on the ground, so that it can not fall. Switch off the power supply in the event of a longer break or when leaving the workplace. Installation Transport Transport of the packed vibrator should be carried out on a wooden pallet using a suitable pallet lifter. It is important to check that the vibrator motor has not suffered any damage due to carelessness during transport. Locating and fixing The vibrator motor can be mounted in any position. Before mounting the vibrator on the structure it is recommended that the centrifugal force be adjusted, see section Adjustment of centrifugal force. The structure must be of adequate stability in order to get the best vibration effect. If the structure is not rigid enough it will be necessary to reinforce it. The reinforcement can be obtained by welding a heavy plate on the structure. The plate is used to mount the vibrator with bolts or bracket. 4. Check that the vibrator is properly sized for the work. To avoid problems with transmission of vibrations that might damage the vibrator, the mounting surface must be flat, clean and unpainted. 11
NOTICE Installation must be carried out by qualified personnel. Local installation regulations must be followed. Make sure that the vibrator is disconnected from the power supply before carrying out any maintenance or installation work on the machine. Bolt mounting When using bolts to mount the vibrator the bolts must be of 8.8 or 10.9 class (high resistance steel according to ISO). The vibrator is screwed directly on the structure or on the mounting plate that is welded on the structure. Tighten the bolt with a toruqe wrench. See section "Maintenance" for the tightening toruqe. Control the tightening toruqe after the first 0 minutes of use and then after every 100 hours. NOTICE If the vibrator is mounted with bolts and nuts, they must be of self locking types. Control of vibrator Before mounting the vibrator it is important to check that the vibrator is in good condition. This check is especially important after along periods of storage. 1. Check that the shaft turns freely and has axial clearance. Make sure that the shaft is not oose. If there is any abnormality contact support personnel immediately. Bracket mounting A B C D 2. Check the motor insulation to ground. Use an insulation tester (Megger) at 2.2 kv potential for five seconds. If there is any abnormality contact support personnel immediately. Normal frequency (,000 r.p.m. Hz and,0 r.p.m. Hz) ER05 use bracket (A) with part number 4700 2920 51. The bracket must be welded to the structure. ER405 and ER5 use mounting kit (B) with part number 4700 1857 71. The bracket kit includes bracket (A), a mounting plate and a bolt set. High frequency (5,400 r.p.m. Hz and 6,000 r.p.m. Hz) ER207B use bracket VT2 (C) with part number 4700 1025 69. The bracket must be welded to the structure. ER407B and ER7B use bracket VT4 (D) with part number 4700 1019 70. The bracket must be welded to the structure. 12
Electrical supply The vibrators must be connected to the supply with a cable of typ HO7RNF (network supply), with one yellowgreen earth cable (A) A NOTICE The ER207B, ER407B and ER7B are equipped with a cable (A07RNF x 2.5 mm 2 of 0.6 m (1.9 ft)) connected to an EC plug. The cable size must be according to the specification on the data plate on the vibrator. The cable must be free from tension and friction, especially in the area close to the vibrator. NOTICE Make sure that the gland is properly locked in the terminal box as well as the cable in the gland. If the gland or cable is not connected correctly the machine will not be dust or waterproof. NOTICE Too long supply cables cause voltage drop, so sometimes it is necessary to increase the cable cross section. In any case follow prescribed regulations. NOTICE Any extension cables must use EC plugs and outlets and in conformity with rules in force. The cable terminations must be preinsulated and have ring ends that suit the pins of the terminal box. Once fixed to the leads check that there is no faulty/incorrect connection (B) which could cause short circuits. Place the washers as shown in the picture. The nut on the connection pins must be locked with the correct toruqe. See section "Tightening toruqe". NOTICE Do not forget to install the flat and knurled washers. The grounding cable must be fixed through tropicalized screw (C). Fit the cover of the terminal box along with the gasket, pay attention not to damage it. At the end of this procedure tighten the cable grip to prevent entry of water or dust. Normal frequency,000 r.p.m. C ER105 The centrifugal force of the ER105 is not adjustable. B The connection to the connection box pins must be performed in accordance with "Electrical connection", instructions shown on the label. Model,000 r.p.m. Hz ER105 Model,0 r.p.m. Hz ER105 ER205ER5 Centrifugal force, Newtons 0 Centrifugal force, Lbs 118 1
Unscrew the eight bolts and remove the end cover at each end of the vibrator. Unscrew the bolts and remove the spacer washers from each end of the rotor. The different possible positions of the eccentric mass can be seen on the table. The settings can also be found on the inside of the covers on the eccentric masses. NOTICE The factory settings for the vibrators are set to position 4. To modify the settings of the eccentric mass remove and rotate the number of sections that is stated in the table. Rotate the sections 180 on the axis and place the sections on the shaft again. Fit the bolts and the spacer washers and tighten the bolts. The adjustment must be carried out on both ends of the rotor. Fit the end covers and the Oring seal. Make sure not to damage the Oring. Settings for ER205 ( Hz) Model,000 r.p.m. ER205 Centrifugal force, Newtons 1 155 2 470 780 4 1100 1 2 4 5 Settings for ER205 (Hz) Model,0 r.p.m. ER205 Centrifugal force, Lbs 1 48 2 144 240 5 1400 4 6 Model,0 r.p.m. ER405 Centrifugal force, Lbs 1 170 2 5 840 4 1175 1 2 4 5 ER5ER705 5 1510 Unscrew the eight bolts and remove the end cover at each end of the vibrator. Unscrew the bolts and remove the spacer washers from each end of the rotor. The different possible positions of the eccentric mass can be seen on the table. The settings can also be found on the inside of the covers on the eccentric masses. NOTICE The factory settings for the vibrators are set to position 4. To modify the settings of the eccentric mass, unscrew the bolt that secures the mobile eccentric mass to the fixed eccentric mass. Offset the mobile mass to the desired setting and tighten the bolt. The adjustment must be carried out on both ends of the rotor. Fit the end covers and the oring seal. Make sure not to damage the Oring. ER5 and ER705 (Hz) Model,000 r.p.m. ER5 ER705 Centrifugal force, Newtons 1 40 00 2 00 8000 70 10000 4 9000 12000 5 100 14000 6 12000 100 1 2 4 5 6 1 2 4 ER5 and ER705 ( Hz) Settings for ER05ER5 ( Hz) Model,000 r.p.m. ER05 ER405 ER5 Centrifugal force, Newtons 1 00 540 700 2 840 1 2040 180 270 80 4 1920 820 4720 5 24 4910 6 000 00 7400 Model,0 r.p.m. ER5 ER705 Centrifugal force, Lbs 1 2 4 1012.5 1 1687.5 2025 145 191 291 2869 5 262.5 47 6 2700 825 1 2 4 5 6 1 2 4 5 6 Settings for ER405 ( Hz) High frequency 6,000 r.p.m. ER207BER7B 14
Unscrew the eight bolts and remove the end cover at each end of the vibrator. Unscrew the bolts and remove the spacer washers from each end of the rotor. The different possible eccentric mass positions can be seen on the table. The settings can also be found on the inside of the covers on the eccentric masses. NOTICE The factory settings for the vibrators are adjusted to position 4. To modify the settings of the eccentric mass remove and rotate the number of sections that is stated in the table. Rotate the sections 180 on the axis and place the sections on the shaft again. Fit the bolts and the spacer washers and tighten the bolts. The adjustment must be carried out on both ends of the rotor. Fit the end covers and the Oring seal. Make sure the oring does not get damaged. Settings for ER207B7B (Hz) Model 6,000 r.p.m. ER207B ER407B ER7B Centrifugal force, Newtons 1 700 1000 14 2 2040 000 480 80 00 700 4 4720 7000 10220 5 9000 1080 1 2 4 5 6 Settings for ER207B7B ( Hz) Model 5,400 r.p.m. ER207B ER407B ER7B Centrifugal force, Lbs 1 120 180 270 2 65 540 810 610 900 1 4 855 12 1890 5 1100 1620 240 6 7400 11000 100 6 145 1980 2970 Before starting maintenance on the machine, clean it in order to avoid exposure to hazardous substances. See Dust and fume hazard. Use only authorised parts. Any damage or malfunction caused by the use of unauthorised parts is not covered by warranty or product liability. When cleaning mechanical parts with solvent, comply with appropriate health and safety regulations and ensure there is satisfactory ventilation. For major service of the machine, contact the nearest authorised workshop. After each service, check that the machine's vibration level is normal. If not, contact the nearest authorised workshop. Every 10 hours of operation (daily) Electrical connections The vibrators are designed for continuous operation. In some applications it is essential to change the direction of the rotation for example with conveyors or feeders to get the force in one direction. This can be achieved by switching two phase wires in the supply cable. Couplings Only vibrators designed with dualvoltage windings are reconnectable. To obtain the correct voltage reconnect the wires as shown in the table. The table for the correct connections is located in the terminal box. Make sure that the nuts that hold the terminal board are tightened after reconnection. Make sure that the rubber gasket between the terminal box and the cover seals is correct. Wiring diagrams for ERseries 1 2 4 5 6 Maintenance Regular maintenance is a basic requirement for the continued safe and efficient use of the machine. Follow the maintenance instructions carefully. A A B B B B B C C C C C Type 2 2 0 1 6 7 8 0 1 6 7 8 Voltage, V 0 0 20 220 240 20 280 400 80 415 400 480 Phases Frequency, Hz 15
D D E E 4 4 220 20 440 4 A B C D E Every 75 hours of operation (or every second week) Lubrication Model ER105 ER205 ER405 ER5 ER05 ER207B ER5 ER705 ER407B ER7B Model ER105 ER205 ER405 ER5 ER05 ER207B ER5 ER705 ER407B ER7B Bearing type 6201. ZZ.QE6 5.ZZ 6 6408 NJ204 NJ206 Grease quantity/ bearing 10 grams* (0.02 lbs.) 25 grams* (0.05 lbs.) 2 grams* (0.004 lbs.) grams* (0.006 lbs.) C C C SKF suffix ECP.C ECP.C Substitution interval (working hours) 2,000 2,000 2,000 2,000 C C C Fag suffix Type of grease TRIBOL 00/100 with T.G.O.A. TRIBOL 00/100 with T.G.O.A. TRIBOL 00/100 with T.G.O.A. TRIBOL 00/100 with T.G.O.A. Tigthening tourqe Locking screws 8.8 M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M0 Locking torque Nm (ft. lb.).92 (2.9) 6.7 (4.8) 9.80 (7.0) 22.55 (16.6) 47.07 (4.7) 78.45 (58.0) 127.48 (94.00) 186.2 (17.00) 264.77 (195.00) 72.65 (275.00) 549.17 (411.00) 696.27 (51.00) 980.65 (720.00) 1274.86 (940.00) Terminal block nut M4 M5 M6 M8 Locking torque Nm (ft. lb.) 1.17 (0.87) 1.96 (1.45) 2.94 (2.17) 6.7 (4.7) Every 100 hours of operation (or monthly) Replacement of the bearings B F G H D E C I ER105 and ER205 do not need any maintenance. Replace any damaged bearings. A ER05, ER405, ER5, ER5, ER705 ER207B, ER407B and ER7B do not require regular greasing, just replacement of the grease after cleaning every 5,000 hours. The user can decide to grease regularly, the interval is approximately 1,200 hours. J K L M 16
Disassembly 1. Unscrew the bolts (A) and remove the washers and end covers (B). 2. Note the position of the eccentrics (C).. Remove the eccentrics (C) together with the bolt (D)and washer (E). 4. Remove the screw (F) and bearing cover (G). 5. Remove the bearing (H) from the bearing bracket (I) and the stator (J). Be careful not to damage the windings in the rotator (K). This is the typical process for disassembly. Some differences can appear between the different types of vibrator. The example is from ER5. The exploded view is only a guide to illustrate the correct procedure. Assembly Before the assembly make sure that the seals (L) and Orings (M) are undamaged. Wash the bearings with white spirit and pack them with the specified quantity of grease. See section "Lubrication" for the recommended type and amount of grease. See the section "Tightening torque" for tightening toruqe of the end cover bolts. 1. Fit the bearings in the bearing brackets by using either a press, or a mallet made of wood or lead to carefully tap the bearing into position. Disposal A used machine must be treated and disposed in such way that the greatest possible portion of the material can be recycled and any negative influence on the environment is kept as low as possible, and in accordance with local restrictions. Always send used filters and drained oil remnants to environmentally correct disposal. The electronic and electrical devices may contain potentially hazardous substances. Do not dispose of them in the nature. Dispose them according to local laws and regulations for the country of use. According to the European directives 2002/95/EC and 2002/96/EC. 2. Fit the stator in the bearing bracket, be careful when fitting the stator (J) not to damage the windings in the rotator (K).. Fit the screw (F) and mount the bearing cover (G). 4. Use the note made earlier to place the eccentrics (C) into the right position. 5. Fit the eccentrics (C), washer (E) and bolt (D). 6. Fit and tighten the end covers (B) with the bolts (A) and washers. Storage Clean the machine properly before storage, in order to avoid hazardous substances. See section Dust and fume hazard. Always store the machine in a dry place. Keep the machine in a safe place, out of the reach of children and locked up. 17
Troubleshooting Problem The vibrator does not start. The motor breaker trips. The vibrator vibrates at low speed. Noise level too high. The concrete vibration is not uniform. Cause No current. The electrical connection inside the connection box is incorrect. The motor is connected on two phases. The RCD trips. The vibrator is broken. Incorrect type or adjustment of the breaker. Incorrect voltage. Not enough power in the supply or converter. Too high amperage consumption. Too high amperage consumption. Too high amperage consumption. Wrong connection. Wrong frequency. Wrong frequency. Friction in the bearings. Broken bearings. Too low centrifugal force. The mounting welds on the form are wrong. The mounting of the fastening bracket on the form is wrong. Too few vibrators. Wrong vibrators choice. Solution Check the mains and the supply cable. Check and change (if necessary) the connection. Check the resistance of the three phases of the stator. Check the resistance of the stator and the the ground insulation of the vibrator. Check if there is any mechanical friction or blockage in the vibrator. The type and adjustment of the motor breaker should be in accordance with the rated amperage of the vibrator. Check the voltage of the mains supply and adjust it if necessary. Check the amps delivered. The form is not strong enough and vibrates. Reinforce the form structure. Resonance of the complete form. Change the dimension of the form. Too much grease in the roller bearings or broken roller bearings. The connection should be in accordance with the voltage. The high frequency vibrator should be connected to a frequency converter. The normal frequency vibrators ( or Hz) have to be connected to the correct mains with the correct frequency. Too much grease in the roller bearings of the high frequency unit. Check the bearings and replace them. Adjust the centrifugal force. The brackets should be welded on a adequate area of the form. The vibrators should be screwed on an adequate area of the form. Add some vibrators where the vibration is missing. Vertical form with high frequency and horizontal forms with normal frequency. 18
Technical data Normal frequency,000 r.p.m. ( Hz) Model ER105 ER205 ER05 ER405 ER5 ER5 ER705 Frequency, r.p.m.,000,000,000,000,000,000,000 Standard voltage 240/400V 240/400V 240/400V 240/400V 240/400V 240/400V 240/400V Phases Frequency Input power, W 40 90 220 5 7 1,1 1,0 Current, A 0.16/0.09 0.0/0.18 0.68/0.9 1.80/1.09 2.0/1..0/1.90 4.20/2. High frequency 6,000 r.p.m. ( Hz) Model ER207B ER407B ER7B Frequency, r.p.m. 6,000 6,000 6,000 Standard voltage 42V 42V 42V Phases Frequency 200 200 200 Input power, W 680 1,000 1,0 Current, A 12. 16. 2. Normal frequency,0 r.p.m. ( Hz) Model ER105 ER205 ER05 ER405 ER5 ER5 ER705 Frequency, r.p.m.,0,0,0,0,0,0,0 Standard voltage 20/4V 220/80V 20/4V 220/80V 20/4V 220/80V 20/4V 220/80V 20/4V 220/80V 20/4V 220/80V 20/4V 220/80V Phases Frequency Input power, W 40 90 220 5 7 1,1 1,0 Current, A 0.16/0.08 0.06 0.0/0.15 0.12 0./0.0 0.24 1.76/0.88 0.70 2.00/1.00 0.85.16/1.58 1.26 4.16/2.08 1.70 High frequency 5,400 r.p.m. ( Hz) Model ER207B ER407B ER7B Frequency, r.p.m. 5,400 5,400 5,400 Standard voltage 42V 42V 42V Phases Frequency 180 180 180 Input power, W 705 1,000 1,0 Current, A 1.00 15.80 2. 19
Electrical supply,000 r.p.m. Hz 6,000 r.p.m. Hz,0 r.p.m. Hz 5,400 r.p.m. Hz Protection index IP 65 (Dustproof) IP 65 (Dustproof) IP 65 (Dustproof) IP 65 (Dustproof) Motor insulation class Class F 155 C (10 F) Class F 155 C (10 F) Class F 155 C (10 F) Class F 155 C (10 F) Ambient temperature 10 to +40 C (14 to 104 F) 10 to +40 C (14 to 104 F) 10 to +40 C (14 to 104 F) 10 to +40 C (14 to 104 F) Voltage 20/4V Hz 42 to 48V200 Hz (frequency converter supply) 20/4V Hz 220/80V Hz 42 to 48V180 Hz (frequency converter supply) Voltage accuracy ±5% ±5% Frequency accuracy ±1% ±1% Noise declaration statement Guaranteed sound power level Lw according to EN ISO 744 in accordance with directive 2000/14/EC. Sound pressure level Lp according to EN ISO 1120. These declared values were obtained by laboratory type testing in accordance with the stated directive or standards and are suitable for comparison with the declared values of other tools tested in accordance with the same directive or standards. These declared values are not suitable for use in risk assessments and values measured in individual work places may be higher. The actual exposure values and risk of harm experienced by an individual user are unique and depend upon the way the user works, in what material the machine is used, as well as upon the exposure time and the physical condition of the user, and the condition of the machine. We, Construction Tools PC AB, cannot be held liable for the consequences of using the declared values, instead of values reflecting the actual exposure, in an individual risk assessment in a work place situation over which we have no control. Noise data Type ER105 ER205 ER05 ER405 ER5 ER5 ER705 ER207B* ER407B* ER7B* Noise Declared values Sound pressure EN ISO 744 LwA 55.00 56.00 57.00 57.00 57. 61.00 6.00 91. 95.6 97.6 *Measured with vibrator connected to Frequency converter CF25M. 20
Dimensions Model Weight, kg (Lbs) A mm (in.) B mm (in.) C mm (in.) D mm (in.) E mm (in.) F mm (in.) G mm (in.) H mm (in.) I mm (in.) J mm (in.) K mm (in.) Mounting ER105 2.70 (5.90) 141 (5.5) 12 (5.2) () 110 (4.) 12 (5.2) 90 (.5) 11 (0.4) 14 (0.5) 48 (1.9) 65 (2.5) () 2 x M10 ER205 4.0 (9.) 216 (8.5) 12 (5.2) () 110 (4.) 12 (5.2) 90 (.5) 11 (0.4) 14 (0.5) 48 (1.9) 65 (2.5) () 2 x M10 ER05 11.00 (24.20) 285 (11.2) 174 (6.8) 78 (.0) 10 (5.1) 15 (5.) 95 (.7) 15 (0.6) 15 (0.6) 49 (1.9) 110 (4.) 45 (1.8) 4 x M12 ER405 20.00 (44.10) 12 (12.2) 200 (7.8) 145 (5.7) 170 (6.6) 179 (7.0) 15 (5.) 14 (0.5) 40 (1.6) 69 (2.7) 176 (6.9) (1.9) 4 x M12 ER5 22.00 (48.) 12 (12.2) 200 (7.8) 145 (5.7) 170 (6.6) 179 (7.0) 15 (5.) 14 (0.5) 40 (1.6) 69 (2.7) 176 (6.9) (1.9) 4 x M12 ER5 44. (98.0) 69 (14.5) 280 (11.0) 1 (5.9) 240 (9.4) 25 (9.25) 190 (7.5) 18 (0.7) (1.9) 97 (.8) 194 (7.6) 70 (2.7) 4 x M16 ER705 46.80 (10.20) 69 (14.5) 280 (11.0) 1 (5.9) 240 (9.4) 25 (9.25) 190 (7.5) 18 (0.7) (1.9) 97 (.8) 194 (7.6) 70 (2.7) 4 x M16 B F I H ØG K E C J A D 21
EC Declaration of Conformity EC Declaration of Conformity We, Construction Tools PC AB, hereby declare that the machines listed below conform to the provisions of EC Directive 2006/42/EC (Machinery Directive), 2006/95/EC (Low voltage), 2004/108/EC (EMC) and the harmonised standards mentioned below. Type Power (W) Rotation (min1) Weight(kg) ER105 40,000 2.70 ER205 90,000 4.0 ER05 220,000 11.00 ER405 5,000 20.00 ER5 7,000 22.00 ER5 1,1,000 44. ER705 1,0,000 46.80 ER207B 680,000 10. ER407B 1,000,000 15. ER7B 1,0,000 2.20 Following harmonised standards were applied: EN12649 Technical Documentation authorised representative: Peter Karlsson Construction Tools PC AB Box 70 91 27 Kalmar Sweden Vice President Design and Development: Erik Sigfridsson Manufacturer: Construction Tools PC AB Box 70 91 27 Kalmar Sweden Place and date: Kalmar, 20121016 22
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