www.wackergroup.com INTERNAL VIBRATOR-FREQUENCY INVERTER IRFUN.../230 0200225en - 10.2002 0007956 100 0008635 100 0007957 100 0008634 100 0007958 100 0008632 100 0008464 100 0008633 100 Operator s Manual
FOREWORD Foreword For your own safety and protection from bodily injuries, carefully read, understand and follow the safety instructions in this manual. Please operate and maintain your Wacker machine in accordance with the instructions in this manual. Your Wacker machine will reward your attention by giving trouble-free operation and a high degree of availability. Defective machine parts are to be replaced as soon as possible. All rights, especially the right for copying and distribution are reserved Copyright by Wacker Construction Equipment AG No part of this publication may be reproduced in any form or by any means, electronic or mechanical, including photocopying, without express permission in writing from Wacker Construction Equipment AG. Any type of reproduction, distribution or saving on data carriers of any type or method not authorized by Wacker represents an infringement of valid copyrights and will be prosecuted. We expressly reserve the right to technical modifications- even without express due notice - which aim at improving our machines or their safety standards. T00778GB 1
TABLE OF CONTENTS FOREWORD 1 SAFETY INSTRUCTIONS 3 General instructions 3 Operation 3 Safety checks 4 Maintenance 4 Transport 4 Maintenance checks 4 TECHNICAL DATA 5 DESCRIPTION 7 Field of application 7 Description of function 7 OPERATION 8 Starting operating 8 Switching the unit off 8 DESCRIPTION/MAINTENANCE 9 Connection 9 Thermal protection 9 Maintenance schedule 9 Disassembly and assembly 10 Maintenance 10 REPAIR INSTRUCTIONS 11 Repair instructions, failures 11 WEAR MEASUREMENTS 14 DIAGRAM 15 EC - CONFORMITY-CERTIFICATE 17 0109762GBIVZ.GB.doc 2
SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS FOR INTERNAL VIBRATORS (POKERS) WITH BUILT-IN FREQUENCY CONVERTERS General instructions 1. IRFUN internal vibrators may only be operated by persons who: * are at least 18 years of age * are physically and mentally fit for this job * have been instructed in operating IRFUN's and proven their ability for the job to the employer * may be expected to carry out the job they are charged with carefully The persons must be assigned for the job of operating the IRFUN by the employer. 2. The IRFUN may only be run as directed for the compaction of concrete, while taking into account the manufacturer s Operating Instructions and under observation of these Safety Instructions. The equipment must be immersed in the mass to be compacted. 3. The persons entrusted with the operation of IRFUN are to be familiarized with the necessary safety precautions relating to the machine. In the case of unusual applications the contractor must compile and issue the necessary additonal instructions. 4. The accident prevention regulations of the employer s liability insurance association for electrical plant and equipment are to be observed and used as a basis for all work with this machine. Operation 1. It must be ensured that electrically driven IRFUNs are only connected to the voltage and frequency specified on the nameplate. The nameplate is located on the inside of the switch housing cover. Moreover, the voltage to which the machine is to be connected is engraved on the switch housing. Choose correct cross section for extension cord. See calculation example and diagram included in this manual. 2. The IRFUN may only be connected to an electric power supply fitted out with a ground fault interrupteur (GFI). Either an universal-sensitive differential current protective breaker must be used or make sure that the IRFUN is the only equipment - no additional equipment allowed -connected to a GFI protective circuit breaker designed for use with loads with non-sinusoidal (distorted) current consumption. Only use power supply sockets with 15 A fuses when connecting IRFUNs to the public mains net. 3. The equipment corresponds to the protection class 1 (grounded/earthed conductor). 4. Ensure that the different components are tightly screwed together before starting the equipment. 5. The IRFUN must not to be switched on and off by inserting the plug into the socket or pulling it out. 6. The power supply cable of the IRFUN must not be used to pull the plug out of the socket. 7. Protect electric cables against heat, oil and sharp edges. 8. Electrical plant and epuipment may only be used if they satisfy the operational and local safety requirements. They must be in perfect working order and must to be kept in this condition. 9. Avoid touching solid objects over longer periods of time when operating the IRFUNs. Also avoid running them without load, i.e. in the air. 10. During work breaks or when the IRFUN is left on its own, the machine is to be switched off and positioned so that it is impossible for it to inadvertently roll away or fall. 11. It is forbidden to operate IRFUN's in potentially explosive environments. 12. Handling the IRFUN is allowed only with suitable protective gloves. Do not touch the vibrator casing tube as it may be hot. SV00033GB 3
SAFETY INSTRUCTIONS 13. Only hold the equipment by its protective hose during operation. Do not hold the IRFUN by its vibrator housing tube, as this could lead to vascular disorders. 14. The transmission of the vibration oscillations into the material to be compacted could lead to a bursting of the shuttering or formwork. Secure the shuttering or formwork as prescribed before compacting concrete with the equipment. Safety checks 1. The effectiviness of the operating, and safety devices must be checked before work is commenced. 2. Check cables and electric plug receptacle to be sure they are not damaged before connecting equipment. 3. Additionally carry out an operational test of the ON/OFF switch and the ground fault interrupter (GFI). 4. The supervisor must be notifed without delay. If defects in the safety devices or other defects are detected which impair the safe operation of the machine. 5. Operations must be discontinued immediately in the event of defects which jeopardise operational safety. 6. Check the vibrator s lower housing tube to be sure that it is not cracked nor damaged and that the screwed connection is not loose. A lost lower tube leads will render the vibrator unserviceable. 7. Check the hose clamps at the connections. ATTENTION! Depending on the switch position the equipment could immediately start running when connected to the current supply. This could also happen in the case of a damaged switch. Maintenance The opening and repairing of the IRFUN may only be carried out by trained and authorized personnel. 1. Only use original spare parts. Modifications to this machine including the adjustment of the maximum engine speed set by the manufacturer are subject to the express approval of Wacker. In case of nonobservance all liabilities shall be refused. 2. The IRFUN must be disconnected from the current supply when carrying out maintenance and repair jobs - pull out the plug from the electric receptacle. 3. Work on electrical components of this machine may only be performed by a specialist. 4. The green/yellow protective earth conductor of the connection cable must be longer so that it does not become detached if the strain relief clamp fails. There is a danger to life and limb if this connection is broken. After repair work, check protective earth conductor for continuity. 5. Protective devices must be correctly mounted back again after maintenance or repair jobs. Screwed connections must be tightened with torques such as indicated in the standards. 6. Clean the IRFUN daily. Do not damage the cables when cleaning with high water pressure equipment. Transport Secure the IRFUN against dropping down during transport. Maintenance checks Depending on the mode of operation and the site conditions, the operational safety of IRFUN's is to be checked as and when required, but at least once every 6 months by a specialist, e.g. at a Wacker customer service station, and if necessary, repaired. In addition, please observe the relevant regulations and guidelines applicable in your country. SV00033GB 4
TECHNICAL DATA IRFUN 38 IRFUN 45 Item no. 0007956... / 0008635... 0007957... / 0008634... Internal vibrator Built in 3-phase motor Voltage Frequency Ratend current Vibrations Dia. vibrator head Length vibrator head Weight (mass), vibrator (without hose connection) Compaction rate in concrete Oil Converter input ratings Alternating current Frequency Ratend current Power input kw: V: Hz: A: min -1 : mm: mm: kg: up to cm: cm 3 : V: Hz: A. kva: 0,47 0,68 214 3~ 200 1,6 2,3 12000 38 45 345 382 2,2 3,5 50 60 5 220-240 1~ 50 / 60 3 4 0,69 0,92 IRFUN 38 The required sound specifications, called-for by the EC-Machine Regulations per Appendix 1, Paragraph 1.7.4.f, are - the sound level, measured at 1m distance, L pa = 79 db(a) This noise level was determined according to ISO 6081 for the sound pressure level (L pa ). The weighted effective value of acceleration, determined according to ISO 8662, Part 1, is under 2,5 m/s 2. This noise and vibration data was determined while the internal vibrator was suspended freely, with the motor running at nominal speed. TD00499GB 5
TECHNICAL DATA IRFUN 57 IRFUN 57k Item no. 0007958... / 0006832... 0008464... / 0008633... Internal vibrator Built in 3-phase motor Voltage Frequency Ratend current Vibrations Dia. vibrator head Length vibrator head Weight (mass), vibrator (without hose connection) Compaction rate in concrete Oil Converter input ratings Alternating current Frequency Ratend current Power input kw: V: Hz: A: min -1 : mm: mm: kg: up to cm: cm 3 : V: Hz: A. kva: 1,04 0,76 214 3~ 200 3,5 2,6 12000 58 400 330 5,6 4,5 85 65 8 220-240 1~ 50 / 60 6 5 1,38 1,15 IRFUN 45 / 57 The required sound specifications, called-for by the EC-Machine Regulations per Appendix 1, Paragraph 1.7.4.f, are - the sound level, measured at 1m distance, L pa = 79 db(a) This noise level was determined according to ISO 6081 for the sound pressure level (L pa ). The weighted effective acceleration value, determined according to ISO 8662, Part 1, is 4 m/s 2. This noise and vibration data was determined while the internal vibrator was suspended freely, with the motor running at nominal speed. TD00499GB 6
DESCRIPTION Field of application The machine is run with single phase current, and is a combination of an internal vibrator and a frequency converter. Description of function The power converter assembly of the transformer carries out a rectification of the input voltage. In the inverted rectifier the direct voltage is converted into three-phase alternating current, at the same time increasing the frequency from 50/60 Hz to 200 Hz. The inverted rectifier operates in "pulse-width modulation" which causes a sinusoidal output to be produced as average value which in turn allows fault-proof operation of the units connected. Due to the smooth starting of the units connected, the supply capacity of the transformer can be used completely. The power converter and the inverted rectifier are triggered by means of a control electronics unit with a microprocessor. 50/60 Hz 200 Hz Power converter 100/115/230/240 V Inverted rectifier Electronics Pulse-width modulation sinusoidal average value T00216GB 7
OPERATION Starting operating Connection: The IRFUN will be factory-set to its nominal voltage. Connect to single phase A.C. 50 or 60 Hz. Operation: When switching the IRFUN on, both the tension and the frequency will be driven up synchronically until reaching their nominal values (soft start). Critical starting currents are thus avoided. ATTENTION! IRFUN's may be connected to a power generator only if the operating voltage of the generator lies within 230/115 V + 15% under any load conditions, the IRFUN alone is connected to the generator and if the manufacturer of the power unit provides for equipment with capacitors to be connected. If the IRFUN is to be driven by a geneator, use only a synchronous generator if possible. Switching the unit off First switch off the IRFUN. Thereafter remove mains plug from the socket. ATTENTION! The IRFUN may be opened only after the plug has been removed from the socket for two minutes as the capacitors mounted have to discharge first of all. Perform work only under off-voltage conditions. T00694GB 8
DESCRIPTION/MAINTENANCE Connection The internal vibrators are to be connected to a 200 cycle Wacker 3-phase frequency and voltage converter with correct output voltage (see list). Thermal protection Additional full motor protection by way of 1 thermal switch per phase! This vibrator has been equipped with a thermal circuit breaker for protection against possible overheating. Disconnect the vibrator and let it cool off if the thermal circuit breaker responds. Maintenance schedule Components Maintenance jobs Maintenance interval Supply line Visual check of cable and switch housing diaphragm. daily Vibrator Oil change. 200 hours T00606GB 9
DESCRIPTION/MAINTENANCE Disassembly and assembly ATTENTION! Only clamp the Internal vibrator in the lower region of the thick-walled nose cap. a Vibrator housing sizes a 38 100 45 120 57 105 57k 80 65 130 65k 105 Maintenance Change SAE 10W oil after approx. 200 working hours. For oil quantity see table. Remove welding point and lower housing for oil change. Clean away used oil from the inside of the exciter housing. Apply pipe threaded seal ergo 4205 to the threads and then screw on the lower part of the housing (torque setting of, see spare parts list). Change the corresponding parts once their wear measurement has been reached. To secure both housing parts apply a welding point at the connection seam. Connection between hose connection point and vibrator housing: Make sure to correctly connect the flat connectors (1) and secure them by way of the heat-shrinkable sleeve (2). See sketch below. T00606GB 10
REPAIR INSTRUCTIONS Repair instructions, failures The luminous diodes 5 + 1 ease the search for defects in case of equipment failures. The equipment must be opened to be able to observe the diodes. ATTENTION! The printed circuit board is under current, even after disconnecting the equipment from the mains, as long as the green luminous diode is on. Only after the condensers have discharged, will the green diode turn off. When the IRFUN recognizes a defect it will disconnect automatically. In this case a red diode will light up when the equipment is connected. Possible failures: Cable interruption between inverter and vibrator head Insulation defect at inverter, motor cable or vibrator head Inverter overload Inverter output overload due to short circuit, earth leakage or defect in vibrator head High / low mains input voltage Operation signal lamp The output frequency of 200 Hz out by means of the potentiometer. Fix the adjusting screw of the potentiometer with a drop of paint. T00695GB 11
T00695GB 12
REPAIR INSTRUCTIONS When in the presence of problems, five red LED s and one green LED incorporated within the inverter make a diagnosis easier. To get to the diagnosis lamps it certainly is necessary to open the inverter housing and then also to apply electrical current (make alive). This job may only be carried out by technically trained personnel or staff correspondingly instructed. ATTENTION! There is a chance of bodily harm if one of the capacitors should explode and if the potting compound is hurtled outward when applying electrical current to the inverter. It is for this reason that safety glasses should be worn on principle and that the area above the capacitors should be kept away from. Under all circumstances carry out a visual inspection of the open inverter before applying an electrical current. Capacitors with a domed (cambered) cover or a projecting higher end have already been previously damaged. Do not apply electrical current under any circumstances to such an inverter. Malfunction Cause Remedy Green LED does not light up. Internal vibrator (IR) not functioning. Green and first red LED light up. IR not functioning. Green and second red LED light up. IR not functioning. Green and third red LED light up. IR not functioning. Green and fourth red LED light up. IR not functioning. Green and fifth red LED light up. IR not functioning. - Supply cable interruption. - Bad contacts. - Broken cable between inverter (FU) and IR. - Defect in the FU electronics. - Short to ground inside the FU or IR. - Temperature inside FU housing to high. - IR runs with difficulty (sluggishly). - Short circuit between FU and IR. - Wrong input voltage, too high or too low. - Check supply line. - Check contacts (switch, plugs) and rework if necessary. - Check electrical wiring and replace if necessary. - Replace FU. - Run insulation test at IR and FU, replace defective parts. - Measure amperages (*) on the output side. - Correct fault in IT. - Find point of short circuit by measuring and then eliminate. - Measure voltage at switch. - Check generator. (*) - see technical data A metal oxide varistor has been included in the input circuit as an additional safety for the equipment against input voltages which are too high. The varistor looks quite similar to a small plate capacitor. Its characteristics are similar to those of a Zener diode (DIN) and it has high current-carrying capacity. Its resistance of more than 1 MW breaks down under extreme circumstances to less than 1 W in less than 50 nanoseconds when overloaded. In this way the electronics of the IRFU are protected against an input voltage that is too high. T00695GB 13
WEAR MEASUREMENTS Type Dimension / limits for vibrator heads and nose caps øl L L L ø L L mm mm mm mm IREN 38 33 (38) 338 (345) 36 (38) 218 IREN 45 38 (45) 372 (382) 42 (45) 333 IREN 57 50 (58) 390 (400) 54,0 (58) 253 IREN 57k 50 (58) 320 (330) 54,0 (58) 213 IREN 65 52(65) 475(490) 58 (65) 322 IREN 65k 52(65) 385(400) 58 (65) 258 Length L and L L to be measured from casing end (Initial measurements) 1 Bold printed figures are condemnation limits. 2 Figures in brackets are original dimensions of new equipment. 3 Replace heads latest when condemnation limits ø (over length L) are reached. 4 Replace end caps latest when condemnation limits L L and øl L are reached. SK00439GB 14
DIAGRAM Selection of required cross section for extension of cables and power lines This procedure takes into consideration: 1. The ohmic and inductive resistance of the line with an admissible loss of voltage of 5% and cos phi = 0,8 as per voltage-frequency-curves. 2. The admissible warming-up of the lines as per VDE standard. Voltage - Frequency - Curves Cross-section area of cable in mm 2 Rated current x length of cable A x m Model: Rated current: Power supply cable: Input cable cross-section: IRFUN 38 3 A 66 m 110 m 176 m 262 m IRFUN 45 4 A 50 m 83 m 132 m 196 m IRFUN 57 6 A 33 m 55 m 88 m 130 m IRFUN 57k 5A 40 m 66 m 105 m 157 m 1,5 mm 2 2,5 mm 2 4 mm 2 6 mm 2 1,5 mm 2 2,5 mm 2 4 mm 2 6 mm 2 1,5 mm 2 2,5 mm 2 4 mm 2 6 mm 2 1,5 mm 2 2,5 mm 2 4 mm 2 6 mm 2 ATTENTION! Use 2.5 sq. mm cable if in doubt about exact extension length. SK00493GB 15
16
EC - CONFORMITY-CERTIFICATE Wacker Construction Equipment AG, Preußenstraße 41, 80809 München hereby certify that the construction equipment specified hereunder: 1. Category: 2. Type: Internal vibrators with inverters IRFUN 38/230 IRFUN 45/230 IRFUN 57/230 (k) 3. Equipment item number: 0007956... 0008635... 0007957... 0008634... 0007958... 0008632... 0008464... 0008633... has been produced in accordance with the following standards: * 98/37/EWG * 89/336/EWG... Dr. Sick Board of Directors File certificate carefully C0002024.GB
18