www.wackergroup.com 0203059en 003 02.2007 Internal vibrators IRSEN-FU Operator's manual
1. Foreword Foreword For your own safety and protection from bodily injuries, carefully read, understand and follow the safety information in this manual. Please operate and maintain your Wacker machine in accordance with the instructions in this operator's manual. Your Wacker machine will reward you with troublefree operation and a high degree of availability. Defective components must be replaced immediately. All rights, especially the right for copying and distribution, are reserved Copyright 2007 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 make technical modifications - even without special notice - which aim at further improving our machines or their safety standards. 3
Table of contents 1. Foreword 3 2. Safety information 5 2.1 General instructions...5 2.2 Operation...5 2.3 Safety checks...7 2.4 Maintenance...8 2.5 Transport...8 2.6 Maintenance checks...8 3. Technical data 9 4. Description 13 4.1 Application...13 4.2 Functional description...13 5. Operation 14 5.1 Starting up...14 5.2 Connection using separate extension cable...15 5.3 Switching off the machine...16 6. Description/maintenance 17 6.1 Protection against overheating...17 6.2 Maintenance schedule...17 6.3 Disassembly and assembly...17 6.4 Maintenance...18 7. Repair instructions 19 7.1 Repair instructions, faults...19 8. Wear dimensions 22 9. Disposal 23 9.1 Environmentally friendly recycling...23 EC Declaration of Conformity 25 DIN EN ISO 9001 Certificate 27 4
Internal vibrators 2. Safety information for internal vibrators with electric motor drive 2.1 General instructions Safety information 2.1.1 Internal vibrators may only be worked on independently by persons who * are at least 18 years of age, * are physically and mentally fit for this job, * have been instructed in operating internal vibrators and have proved their ability for the job to the employer and * may be expected to carry out the job they are charged with carefully. They must have been assigned to work on the internal vibrators by the company. 2.1.2 Internal vibrators are to be applied only for compacting work. Both the manufacturer's operator's manual and this safety information must be observed. The machine must be immersed in the mass to be compressed. 2.1.3 The persons charged with the operation of internal vibrators must be made familiar with the necessary safety measures relating to the machine. In case of extraordinary uses, the employer shall give the necessary additional instructions. 2.1.4 Observe the accident prevention regulations set forth by the professional association for electrical equipment and material and use them as a basis during all work performed with this machine. 2.1.5 This machine generates noise that exceeds the country-specific permissible noise levels (individual rating level). It may therefore be necessary to wear ear protection. 2.2 Operation 2.2.1 You must ensure that the internal vibrators with electric motor drive are only attached to the voltage and frequency indicated on the nameplate. The nameplate is located on the inside of the switch box cover. Choose correct cross section for extension cord. SV00042en.fm 5
Safety information Internal vibrators 2.2.2 These internal vibrators may only be connected to electric power supplies with a fault current protective switch. Used inverters must correspond to VDE 0530. For voltages greater than 42 volts, they must be provided with protective breakers (-). When used on construction sites, inverters must be operated via a separate supply point, which is provided with a fault current protective switch. 2.2.3 Vibrators, which are operated with protective low voltage 42 volts, correspond to class rating III. Vibrators with a higher operating voltage correspond to class rating I (grounded conductor). 2.2.4 Prior to starting the internal vibrator, make sure that the components are screwed on securely. 2.2.5 Activated internal vibrators should not come into contact with any solid objects over a long period of time, long running times in the air must be avoided. 2.2.6 When taking a break or when leaving the internal vibrator, the operator must switch off the machine and park it securely in such a way to ensure that it cannot tip over or fall down. 2.2.7 The power cable of the internal vibrator must not be used to pull out the plug from the plug receptacle. Do not insert or pull out the power plug as a means of turning the internal vibrator on or off. 2.2.8 Protect electric cable from heat, oil, and sharp edges. 2.2.9 Appropriate protective gloves must always be worn when handling internal vibrators. Do not touch the hot vibration body. 2.2.10 The protective hose must be used to guide the machine during operation. Using the vibration body to guide the internal vibrator can cause vascular diseases. 2.2.11 The transmission of vibration oscillations to the material to be compacted can damage or destroy the casing. Casings must be secured according to regulations before using the machine. 2.2.12 Electrical equipment and material may only be used if they comply with operational and local safety requirements. They must be in proper condition and this condition is to be maintained. 2.2.13 Do not operate internal vibrators in areas where explosions may occur. SV00042en.fm 6
Internal vibrators 2.3 Safety checks Safety information 2.3.1 Before starting operation, the operator has to check that all control and safety devices are functioning properly. 2.3.2 Prior to connecting the machine, check the electric cable and socket for damage on a regular basis. 2.3.3 Also check the proper functioning of the On/Off switch and the fault current protective switch. 2.3.4 If defects on the safety devices or other defects impairing the operational safety of internal vibrators are observed, the supervisor must be informed immediately. The machine must not be commissioned. 2.3.5 If there are defects jeopardizing operational safety, the machine has to be switched off immediately. 2.3.6 The housing tube and the sealing cap are wear parts and must be replaced when the minimum wear measurements have been reached. Refer to the operator's manual for information concerning the wear dimensions for internal vibrators. 2.3.7 Check the bottom part of the pipe for cracks, damage or loose screw connections. The vibration cylinders are not suitable for use if the bottom part of the pipe is missing. 2.3.8 Check the clamps on the connections. 2.3.9 The machine can start to run immediately as soon as it is connected to the mains depending on the switch setting. This is also possible if the switch is defective. SV00042en.fm 7
Safety information 2.4 Maintenance Internal vibrators Opening and repairing internal vibrators may only be carried out by trained and authorized technicians. 2.4.1 Only use original spare parts. Modifications to this machine are subject to the express approval of Wacker. In case of non-observance, all liability shall be refused. 2.4.2 Disconnect the internal vibrator from the electrical power supply system by pulling out the mains plug before carrying out maintenance and repair work. 2.4.3 Work on the electric parts of the machine may only be carried out by skilled technicians. 2.4.4 The green-yellow grounded conductor of the connecting cable must be longer so that it will not be torn off if the strain relief fails. If interrupted, it can cause fatal injury. After conducting repairs, check the grounded conductor for continuity. Double insulated machines and machines with protective low voltage are not provided with a grounded conductor. 2.4.5 As soon as maintenance and repair jobs have been completed, all safety devices must be properly reinstalled. Screws must be tightened according to the tightening torques specified in the standards. 2.4.6 Clean the internal vibrator daily. Make sure not to damage the lines when using high pressure washers. 2.5 Transport 2.5.1 Secure internal vibrators against falling down during transportation. 2.6 Maintenance checks 2.6.1 According to the conditions and frequency of use, internal vibrators must be checked for safe operation by a technician, for example at a WACKER service station, at least once every 6 months and repaired if necessary. Please observe the appropriate rules and regulations valid in your country. SV00042en.fm 8
3. Technical data Technical data IRSEN-FU 38 IRSEN-FU 45 Item no. Laser 0008727 0008730 0610155 0008921 0008726 0008729 0610154 0008922 Vibrator head Integrated three-phase AC motor Voltage Frequency Rated current Vibrations Vibrator diameter Vibrator length Vibrator weight (mass) (without hose connection) Effective diameter in concrete kw: V: Hz: A: rpm: mm: in: mm: in: kg: lb: cm: in: 0.475 0.47 0.682 0.68 214 3~ 200 1.6 2.3 12,000 38 (1.5) 45 (1.8) 345 (14) 382 (15) 2.2 (4.9) 3.5 (7.7) < 50 (20) < 60 (24) Oil type SAE 0W-30 Oil quantity cm 3 : in 3 : 8 (0.5) Inverter / mains connection value Alternating current V: 220-240 1~ 110-130 1~ 220-240 1~ 110-130 1~ Frequency Hz: 50 / 60 Current A: 3 6 4 8 TD00702en.fm 9
Technical data IRSEN-FU 38 IRSEN-FU 45 Power kva: kw: 0.69 0.55 0.92 0.74 Sound pressure level L pa at operator's station db(a): 79 The weighted effective acceleration value, determined according to EN ISO 5349 m/s 2 : 2.5 These noise and vibration figures were calculated with the internal vibrator being freely suspended in air at the nominal speed of the drive motor. Required cross section for extension of cables TD00702en.fm 10
Technical data Item no. Vibrator head 0008725 0008728 IRSEN-FU 57 0008923 Integrated three-phase AC motor Voltage Frequency Rated current Vibrations Vibrator diameter Vibrator length Vibrator weight (mass) (without hose connection) Effective diameter in concrete kw: V: Hz: A: rpm: mm: in: mm: in: kg: lb: cm: in: 1.04 214 3~ 200 3.5 12,000 58 (2.3) 400 (16) 5.6 (12.3) < 85 (33) Oil type SAE 0W-30 Oil quantity cm 3 : in 3 : 12 (0.7) Inverter / mains connection value Alternating current 220-240 1~ 110-130 1~ Frequency 50 / 60 Current 6 12 Power kva: kw: 1.38 1.1 TD00702en.fm 11
Technical data Sound pressure level L pa at operator's station db(a): IRSEN-FU 57 79 The weighted effective acceleration value - measured according to EN ISO 5349 m/s 2 : 2.5 These noise and vibration figures were calculated with the internal vibrator being freely suspended in air at the nominal speed of the drive motor. Required cross section for extension of cables TD00702en.fm 12
4. Description Description 4.1 Application The machine is run with single phase current, and is a combination of an internal vibrator and a frequency converter. 4.2 Functional description 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 micro-processor. 50/60 Hz 200 Hz Rectifier 100/115/230/ 240 V D.c.-a.c. converter Electronics Pulse width modulation Sinusoidal average T01036en.fm 13
Operation 5. Operation 5.1 Starting up Danger to life Connection: The equipment has been set to its nominal current at the factory. Hook up to single-phase alternating current with 50 or 60 Hz. Assembly instructions for the version without plug receptacle Danger of electrocution! Only a qualified electrician is permitted to assemble the plug and perform a safety check according to the directives in effect. Observe the assembly instructions! Connection: Both voltage and frequency will run up synchronously until they reach their nominal value (soft start) once the equipment has been connected to a power supply; this helps to avoid critical current intensities during start-up. The equipment is suitable for connection to power generators if the generators operating voltage stays within the limits of 230/115 V + 15 %, and if the manufacturer of the generator allows the connection of consumers equipped with capacitors. If possible choose a synchronous generator if the equipment is to be run off a power generator. T01036en.fm 14
5.2 Connection using separate extension cable Operation The required cross-section is dependent on the length of the extension cable: Type Length L m Cross-section in mm 2 38/115 < 16 1,5 < 27 2,5 < 43 4 < 65 6 38/230 < 66 1,5 < 110 2,5 < 176 4 45/115 < 12 1,5 < 20 2,5 < 32 4 < 49 6 45/230 < 50 1,5 < 83 2,5 < 132 4 57/115 < 13 2,5 < 21 4 < 32 6 < 53 10 57/230 < 33 1,5 < 55 2,5 < 88 4 57k/230 < 40 1,5 < 66 2,5 < 105 4 T01036en.fm 15
Operation 5.3 Switching off the machine First switch off the equipment. Then pull the mains plug from the socket. T01036en.fm 16
Description/maintenance 6. Description/maintenance 6.1 Protection against overheating This machine is protected against overheating by means of a thermal circuit breaker. Every phase is equipped with a separate thermal circuit breaker. If the thermal circuit breaker is activated, switch off the machine and allow it to cool down. 6.2 Maintenance schedule Component Maintenance work Maintenance interval Feed line Visual check - cables and switch box membrane Daily 6.3 Disassembly and assembly Only clamp the Internal vibrator in the lower region of the thick-walled nose cap. a Bottle sizes a 38 100 45 120 57 105 57k 80 65 130 65k 105 T01036en.fm 17
Description/maintenance 6.4 Maintenance 6.4.1 A replacement of the corresponding parts is necessary once the wear measures have been reached. Seal housing components at joint with ergo 4205 and guard against loosening with a welding point. * for IR... 30: Replace complete vibrator head. * for IR... 38/45/57: Connecting lines between hose connection and vibrator head: Make sure to correctly connect the flat connectors (1) and secure them by way of the heat-shrinkable sleeve (2). See illustration. * for IR... 65: Crimp connectors on both sides to connect electric connection lines. 6.4.2 After opening the vibrator head the correct oil level must be ensured prior to assembly (see technical data). T01036en.fm 18
Repair instructions 7. Repair instructions Work on the electric parts of the machine may only be carried out by skilled technicians. 7.1 Repair instructions, faults The equipment may only be opened at least about 5 minutes after the plug was pulled from the socket; this will give the capacitors mounted inside the housing time to dump their charge. Maintenance work may only be carried out be trained personnel. Possible errors: Interruption of the cable connection inverter/vibrating cylinder Insulation error of the inverter, the engine cable or the vibrating cylinder Inverter is overloaded The output stage of the inverter is overloaded due to a short-circuit, ground fault or error in the vibrating cylinder Line input voltage too high / too low Operating control lamp As long as the green LED is lit, the circuit board is electrically charged - even after you switch off the line voltage. The green LED goes out when the condensers are discharged. The diagnostic lamps built into the inverter, five red LEDs and a green LED, help you troubleshoot any problems you may encounter. However, this requires, that you open the inverter housing and apply voltage. This must be carried out by a specialist or a properly instructed employee. T01036en.fm 19
Repair instructions There is a risk of injury should a condenser explode when voltage is applied and, as a result thereof, potting compound is ejected. This is why you should always wear eye protection and avoid the area right above the condensers. Before you apply voltage, always carry out a visual inspection of the opened inverter. Condensers with bulged tops or ones that are higher than the others are already damaged. You must not apply voltage to this inverter! If a red LED lights up when you turn on the machine, the machine has shut down because of a detected error. Malfunction Cause Remedy Green LED is not lit. 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. - Cable disruption between frequency converter (FU) and IR. - Defect in the FU electronics. - Short to ground inside the FU or IR. - Temperature inside FU housing. - IR runs sluggish. - Short circuit between FU and IR. - Incorrect input voltage, too high or too low. - Check supply line. - Check contact transitions (switches, connectors) and rework if necessary. - Check cables and replace if faulty. - Replace FU. - Insulation measurements at IR and FU, replace faulty components. - Measure amperages (*) on the output side. - Correct fault in IT. - Locate the short circuit by measurements and remove. - Measure voltage at the switch. - Check generator. (*) - see Technical Data T01036en.fm 20
Repair instructions 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 currentcarrying capacity. Its resistance of more than 1 MΩ breaks down under extreme circumstances to less than 1 Ω in less than 50 nanoseconds when overloaded. This helps protect the electronic circuitry against high input voltages. The output frequency of 200 Hz out by means of the potentiometer. Fix the adjusting screw of the potentiometer with a drop of paint. T01036en.fm 21
Wear dimensions 8. Wear dimensions Machine type Dimensions of the vibrator head and screwed nose caps (mm) øl L L L ø L L IR... 30 28 (30) 347 (353) - - IR... 38 33 (38) 338 (345) 36 (38) 218 IR... 45 38 (45) 372 (382) 42 (45) 333 IR... 57 IR... 57k 50 (58) 390 (400) 320 (330) 54,0 (58) 54,0 (58) 253 213 IR... 65 IR... 65k 52 (65) 475(490) 385(400) 58 (65) 58 (65) 322 258 Measure lengths L and L L at the end of the housing pipe (initial measurements) * Dimensions in bold are wear dimensions. * Dimensions in brackets are original dimensions of new machines. * Replace vibrator head at the latest when the minimum diameter ø (measured in the length L) is reached. * The screwed nose caps must be replaced at the latest when the minimum lengths L L and øl L have been reached. SK00630en.fm 22
9. Disposal Disposal 9.1 Environmentally friendly recycling Recycle the machine in an environmentally friendly way observing the regional regulations and directives, e.g. the European Directive for old electrical and electronic equipment. Do not dispose of the machine in household rubbish. It must be disposed of separately. T01088en.fm 23
Disposal T01088en.fm 24
EC Declaration of Conformity Wacker Construction Equipment AG, Preußenstraße 41, 80809 München certifies that the construction machine: 1. Category: 2. Model: 3. Machine type number: Innenvibrator mit Umformer IRFUN 38, IRFUN 45, IRFUN 57 IRSEN-FU 38, IRSEN-FU 45, IRSEN-FU 57 0007956, 0007957, 0007958, 0008464, 0008481, 0008494, 0008496, 0008611, 0008612, 0008613, 0008628, 0008629, 0008630, 0008631, 0008632, 0008633, 0008634, 0008635, 0008636, 0008637, 0008638, 0008639, 0008640, 0008725, 0008726, 0008727, 0008728, 0008729, 0008730, 0008921, 0008922, 0008923, 0008928, 0610107, 0610108, 0610109, 0610110, 0610153, 0610154, 0610155 was produced in accordance with the following directives: 98/37/EEC 89/336/EEC 73/23/EEC Please keep this document in a safe place C0002524en.fm Dr. Stenzel Head of Research and Development
DIN EN ISO 9001 Certificate
Wacker Construction Equipment AG Preußenstraße 41 80809 München Deutschland Tel.: +49-(0)89-354 02-0 Fax: +49-(0)89-354 02-390 Wacker Corporation P.O. Box 9007 Menomonee Falls, WI 53052-9007 USA Tel.: +1(1)262-255-0500 Fax: +1(1)262-255-0550 Support: 800-770-0957 Wacker Machinery (HK) Ltd. Skyline Tower, Suite 2303, 23/F 39 Wang Kwong Road, Kowloon Bay Hong Kong Tel.: +852-2406-6032, Fax: +852-2406-6021