Wacker Neuson AR 54/3/200/400 User manual

Brand: Wacker Neuson

Model: AR 54/3/200/400

Type: User manual

This manual is also suitable for

AR 54/3,6/460 US

Wacker Neuson AR 54/3/200/400 excels in concrete compaction, especially for use on formworks, molding and casting tables. Its high power density at 200/400 Hz ensures excellent compaction results. Thanks to its robust construction and high-quality materials, it can withstand even the toughest conditions on the construction site.

Operator´s Manual

EXTERNAL VIBRATORS

AR 54

0200143en 005

12.2009

Manufacturer

Wacker Neuson SE

Preußenstraße 41

80809 München

www.wackerneuson.com

Tel.: +49-(0)89-354 02-0

Fax: +49-(0)89-354 02-390

Translation of the original operator’s manual in German

1 Foreword

This operator's manual contains information and procedures for the safe opera-

tion and maintenance of your Wacker Neuson machine. In the interest of your

own safety and to prevent accidents, you should carefully read through the safety

information, familiarize yourself with it and observe it at all times.

This operator's manual is not a manual for extensive maintenance and repair

work. Such work should be carried out by Wacker Neuson service or authorized

specialists.

The safety of the operator was one of the most important aspects taken into con-

sideration when this machine was designed. Nevertheless, improper use or in-

correct maintenance can pose a risk. Please operate and maintain your Wacker

Neuson machine in accordance with the instructions in this operator's manual.

Your reward will be troublefree operation and a high degree of availability.

Defective machine parts must be replaced immediately!

Please contact your Wacker Neuson representative if you have any questions

concerning operation or maintenance.

No part of this publication may be reproduced in any form or by any means, elec-

tronic or mechanical, including photocopying, without the expressed written per-

mission of Wacker Neuson.

Any type of reproduction, distribution or storage on data media of any type and

form not authorized by Wacker Neuson represents an infringement of copyright

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 stan-

dards.

Table of contents

1. Foreword 3

2. Safety information 5

2.1 Principle .................................................................................................5

2.2 Qualification of the operating personnel ................................................7

2.3 Protective gear ......................................................................................8

2.4 Transport ...............................................................................................8

2.5 Operating safety ....................................................................................9

2.6 Safety during the operation of electric appliances .................................9

3. Technical data 13

4. Description 14

4.1 Operating range ..................................................................................14

4.2 Description of function .........................................................................14

4.3 Note .....................................................................................................14

4.4 Connection ..........................................................................................14

4.5 Wiring diagram ....................................................................................15

5. Maintenance 16

5.1 Motor casing ........................................................................................16

5.2 Maintenance schedule ........................................................................16

6. Diagram 17

7. Eccenftric 18

8. Assembly Instructions 20

9. Disposal 21

9.1 Environmentally friendly reuse ............................................................21

Declaration by the manufacturer 23

DIN EN ISO 9001 Certificate 25

External vibrators

SV00079GB.fm 5

2. Safety information

2.1 Principle

State of the art

This machine has been constructed with state-of-the-art technology according to

the recognized rules of safety. Nevertheless, when used improperly, dangers to

the life and limb of the operator or to third persons or damage to the machine or

other materials cannot be excluded.

Proper use

The machine may only be used for the excitation of all kinds of molds and

formworks, vibratory tables, vibratory stands for the compaction of fresh

concrete.

Other special applications must be checked and released by WACKER.

Its proper use also includes the observance of all instructions contained in this

operator's manual as well as complying with the required service and

maintenance instructions.

Any other use is regarded as improper. Any damage resulting from improper use

will void the warranty and the liability on behalf of the manufacturer. The operator

assumes full responsibility.

Structural modifications

Never attempt to modify the machine without the written permission of the

manufacturer. Failure to do so will endanger your safety! In addition, this will void

the warranty and the liability on behalf of the manufacturer.

Requirements for operation

The ability to operate the machine safely requires:

 Proper transport, storage and setup.

 Careful operation.

 Careful service and maintenance.

Operation

Operate the machine only as intended and only when in proper working

condition.

Operate the machine in a safety-conscious manner with all safety devices

attached and enabled. Do not modify or disable any safety devices.

Before starting operation, check that all control and safety devices are

functioning properly.

Never operate the machine in a potentially explosive environment.

External vibrators

SV00079GB.fm 6

Maintenance

Regular maintenance is required in order for the machine to operate properly and

reliably over time. Neglected maintenance work can make the machine

dangerous to use.

 Strictly observe the prescribed maintenance intervals.

 Do not use the machine if it requires maintenance or repairs.

Malfunctions

If you detect a malfunction, you must shut down and secure the machine

immediately.

Eliminate the malfunctions that impair safety immediately!

Have damaged or defective components replaced immediately!

For further information, please see the chapter Troubleshooting.

Spare parts, accessories

Only use spare parts and accessories from WACKER. Non-compliance will

exempt the manufacturer from all liability.

Exclusion of liability

WACKER will refuse to accept liability for injuries to persons or for damage to

materials in the following cases:

 Structural modifications.

 Improper use.

 Improper handling.

 Use of spare parts and accessories not produced by WACKER.

Operator's manual

Always keep the operator's manual near the machine or near the worksite for

quick reference.

If you have misplaced the operator's manual or require an additional copy,

contact your WACKER representative or download it from the Internet

(www.wackerneuson.com).

Always hand over this operator's manual to other operators or to the future owner

of the machine.

Country-specific regulations

Observe the country-specific regulations, standards and guidelines in reference

to accident prevention and environmental safety, for example those pertaining to

hazardous materials and wearing protective gear.

Complement the operator's manual with additional instructions taking into

account the operational, regulatory, national or generally applicable safety

guidelines.

External vibrators

SV00079GB.fm 7

Operator's controls

Always keep the operator's controls of the machine dry, clean and free of oil or

grease.

The function of the operator's controls must not be manipulated or rendered

ineffective.

Cleaning

Always keep the machine clean and be sure to clean it each time you have

finished using it.

Do not use gasoline or solvents. Danger of explosion!

Checking for signs of damage

Inspect the machine when it is switched off for any signs of damage at least once

per work shift.

Do not start the machine if there is visible damage or defects.

Have any damage or defects eliminated immediately.

2.2 Qualification of the operating personnel

Operator qualifications

Only trained personnel are permitted to start and operate the machine. The

following rules also apply:

 You are physically and mentally fit.

 You have received instruction on how to independently use the machine.

 You have received instruction in the proper use of the machine.

 You are familiar with required safety devices.

 You are authorized to start machines and systems in accordance with the

standards governing safety.

 You have been assigned to work on the machine by your company.

Incorrect operation

Incorrect operation or misuse by untrained personnel can endanger the health

and safety of the operator and also cause machine and material damage.

Operating company responsibilities

The operating company must make the operator's manual available to the

operator and ensure that the operator has read and understood it.

External vibrators

SV00079GB.fm 8

Work recommendations

Please observe the recommendations below:

 Work only if you are in a good physical condition.

 Work attentively, particularly as you finish.

 Do not operate the machine when you are tired.

 Carry out all work calmly, circumspectly and carefully.

 Never operate the machine under the influence of alcohol, drugs or

medication. This can impair your vision, reactions and your judgment.

 Work in a manner that does not endanger others.

2.3 Protective gear

Work clothing

Clothing should be appropriate, i.e. should be close-fitting but not restrict your

movement.

Do not wear long hair loosely, loose clothing or jewelry including rings. These

objects can easily get caught or be drawn in by moving machine parts.

Personal protective gear

Wear personal protective gear to avoid injuries or health hazards:

 Non-skid, hard-toed shoes.

 Work gloves made of durable material.

 Overalls made of durable material.

 Hardhat.

 Ear protection.

Ear protection

This machine generates noise that exceeds the country-specific permissible

noise levels (individual rating level). It may therefore be necessary to wear ear

protection.

WACKER recommends that you always wear ear protection.

2.4 Transport

Switching off the machine

Before you transport the machine, switch it off and pull the mains plug out of the

plug receptacle.

Transporting the machine

Secure the machine on the transport device against tilting, falling or slipping.

Restarting

Machines, machine parts, accessories or tools that were detached for transport

purposes must be re-mounted and fastened before restarting.

Only operate in accordance with the operating instructions.

External vibrators

SV00079GB.fm 9

2.5 Operating safety

Work environment

Familiarize yourself with your work environment before you start work. This

includes e.g. the following items:

 Obstacles in the work and traffic area.

 The load-carrying capacity of the ground.

 The measures needed to cordon off the construction site from public traffic.

 The measures needed to secure walls and ceilings.

 Options available in the event of an accident.

Starting the machine

Observe the safety information and warnings symbols located on the machine.

Never attempt to start a machine that requires maintenance or repairs.

Start the machine as directed in the operator's manual.

Vertical stability

Always make sure that you maintain a safe distance when working with the

machine. This applies particularly when working on scaffoldings, ladders, etc.

Switching off the machine

Switch the machine off and pull the mains plug out of the plug receptacle: before

taking a break or if the machine will not be used.

Store the machine in such a way that it cannot tilt, fall or slip.

2.6 Safety during the operation of electric appliances

Specific regulations for electrical appliances

Observe the safety information provided in the brochure General Safety

Information which is included in the scope of delivery of your machine.

Also observe the country-specific regulations, standards and guidelines in

reference to accident prevention in connection with electrical equipment and

machines.

External vibrators

SV00079GB.fm 10

Electric power supply with residual current protective device (42 V AC)

Note: The rated voltage is indicated on the nameplate of your machine.

The machine may only be connected to an electric power supply with all machine

parts in proper working condition:

 Mains plug.

 Power cable over the entire length.

There must be at least one of the following safety devices if connected to a

stationary or mobile generator:

 Transformer with safe separation in accordance with EN 60742.

 Motor generator with equally separated windings.

Note: Observe the respective national safety regulations!

Power supply with residual current protective device (> 50 V AC)

Note: The rated voltage is indicated on the nameplate of your machine.

The machine can be connected to a 15 A/16 A shock-proof plug receptacle

(continental type) with a corresponding overload protection.

One of the following fault current protective switches is required:

 Standard fault current protective switch (AC sensitive, type A).

 AC/DC sensitive fault current protective switch (type B).

The machine may only be connected to an electric power supply with all machine

parts in proper working condition:

 Mains plug.

 Power cable over the entire length.

The machine may only be connected to an electric power supply with the

protective earth (PE) connector intact.

There must be at least one of the following safety devices if connected to a

stationary or mobile generator:

 Fault current protective switch

 Isolation (earth leakage) monitor

 IT-net

Note: Observe the respective national safety regulations!

Extension cable

The machine may only be operated with undamaged extension cables!

Only use extension cables with grounded conductor and correct connection of

the grounded conductor to the plug and coupling (not for 42 V machines).

Only use extension cables which are suitable for use at construction sites:

Average rubber hose line H05RR-F or better – WACKER recommends

H07RN-F.

Immediately replace damaged extension cables (e.g. tears in the sheathing) or

loose plugs and couplings.

External vibrators

SV00079GB.fm 11

Protecting the power cable

Do not use the power cable to pull or lift the machine.

Do not unplug the mains cable by pulling on the cable.

Protect the mains cable from heat, oil and sharp edges.

If the power cable is damaged or the plug is loose, have it replaced immediately

by your WACKER representative.

2.7 Safety during the operation of external vibrators

Attaching the safety strap

If using the external vibrator in conjunction with a clamp, always attach the clamp

to the formwork using the safety belt supplied.

Attach the safety belt above the external vibrator securely to the formwork. The

safety belt should be taut without slack to ensure the clamp and the external

vibrator are caught by the safety belt in the event of a fall and stopped from falling

too far.

Motor protection against overload

To protect the motor against overload, WACKER recommends the use of a

motor-protective circuit-breaker.

Using stable formwork

Only use stable molds and formwork for attaching the external vibrator. Tighten

the fastening screws.

Molds and formworks that are not firm enough or loose connections may

overload the motor or result in being damaged themselves.

Check whether your formwork is suitable for receiving external vibrators:

 Attachment possibility.

 Sufficient stability for the used external vibrator type (dependent on the

performance).

Your WACKER representative will be happy to assist you.

Using the correct clamp

Attach the external vibrator using the clamp which is suitable for the external

vibrator and the formwork.

2.8 Maintenance

Maintenance work

Service and maintenance work must only be carried out to the extent described

in these operating instructions. All other procedures must be performed by your

WACKER representative.

For further information, please see the chapter Maintenance.

External vibrators

SV00079GB.fm 12

Disconnecting the machine from the electric power supply

Before carrying out service or maintenance work, pull the mains plug out of the

plug receptacle in order to disconnect the machine from the electric power

supply.

Technical data

TD00348GB.fm 13

3. Technical data

AR 54/3/200/440 AR 54/3,6/440 AR 54/3,6/460

Item no.

0007299 0007027 0007812

Length x width x height

mm:

352 x 150 x 186

Operating weight

kg:

15,7 14,9

Drive

High-frequency squirrel-cage induction motor to be connect-

ed up with frequency and voltage transformer

Voltage

200/400 220/440 230/460

Frequency

Hz:

50 60

Rated current

3,4/1,7 3,2/1,6 3/1,5

Vibrations

min

-1

3000 3600

Centrifugal force

kN:

8,30 8,54

Type of protection IP65

Sound pressure level L

operator’s station

dB (A):

below 70

The sound value was determined according to EN ISO 11204 for sound pressure levels (L

), at

nominal motor rpm's and while freely hanging in the air.

Description

T00508GB.fm 14

4. Description

4.1 Operating range

To be used in pre-cast concrete factories for the vibration of forms of

all kinds as well as for installation on vibrating tables, vibrating blocks,

and machines. In building construction and civil engineering to be used

as form vibrators in all pre-cast concrete factories to fit planks, plates,

etc.

4.2 Description of function

In order to be able to mount the external vibrator to the form, resp.

mould, a faced steel plate of approx. 20 mm thickness has to be

attached to the respective mounting point, to which the external

vibrator is affixed by means of four screws M16 - 8.8 (see Assembly

instructions).

4.3 Note

The form, resp. mould material has to have perfect connections and

closures, which might have to be reinforced for the best possible

transmission of vibration, otherwise increased current consumption or

mechanical damage may result from overload of the external vibrator.

4.4 Connection

Prior to connection please check:

The voltage used has to correspond to the data shown on the rating

plate.

Connect the following external vibrator directly to the power net (as

indicated by rating plate):

AR 54/3/200/400

AR 54/3,6/440

AR 54/3,6/460

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!

Danger to life

Description

T00508GB.fm 15

4.5 Wiring diagram

Vast voltage 400/440/460 V

black

blue

brown

joined in coil end green/yellow

Normal voltage 200/220/230 V

black

blue

brown

joined in coil end green/yellow

Adjustment of centrifugal force

For the versatile requirements, the centrifugal force of the external

vibrator can be adjusted in compliance with the technical data. Take

care that the nuts are tightened again after adjustment.

Maintenance

T00186GB.fm 16

5. Maintenance

5.1 Motor casing

The bearings of the external vibrator (1) can be lubricated from the outside. Remove

closure screws (12) from motor casing (7). Grease with appropriate grease gun.

Screw closure screws (12) back in agai

5.2 Maintenance schedule

Parts Maintenance Jobs Maintenance intervals

Supply cable (11)

Check for perfect condition:

replace defective cable.

daily

External vibrator (1)

Retighten all accessible screw

connections.

after first 20 hours

Bearing in motor

housing (7)

Lubricate. (Unirex N2) 200 hours

Diagram

SK00001GB.fm 17

6. 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 (table of required minimum cross section).

ATTENTION! The larger one of both cross sections has to be chosen.

Example:

Nominal voltage 3 ~ 400 V, 200 Hz

Rated current 15 A Line length 100 m

15 A x

50 m = 1900 A x m

Cross section as per diagramm: 2,5 mm

Cross section as per table: 15 A : 1mm

Chosen cross section: 2,5 mm

Voltage - Frequency - Curves

Cross-section area of cable in mm

Minimum cross-section

area according to VDE

Max. Max.

Cable load fuse

115 10

1,5 18 10/3~16/1~

2,5 26 20

434 25

644 35

10 61 50

16 82 63

Rated current x length of cable A x m 25 108 80

Eccenftric

T00509GB.fm 18

7. Eccenftric

AR 54/3/200/440 AR 54/3,6/440 AR 54/3,6/460

Flywheel No. 0034236 0034236 0034236

Quantity per machine 28 20 20

External diameter (D) 134 134 134

Thickness = 2 Borehole diameter (d) = 24

WARNING!

The flywheels of this device consist of several 2 mm discs which are at-

tached to the shaft all in the same direction or at an angle of 120

to each

other. Hence, the centrifugal forces can be adjusted in several different

ways:

1. By removing individual flywheel discs

2. By turning individual flywheel discs

If the maximum centrifugal force is not required, proceed according to item

1 to obtain a low flywheel effect, and thus short starting and slowing-down

times.

AR 54/3,6/440; AR 54/3,6/460

Number of Number of Centrifu- Moment Number of Number of Centrifu- Moment

eccentric eccentric gal force inertia eccentric eccentric gal force inertia

weights per weights per weights per weights per

side Pos. 1 side Pos. 2 kN 10

-4

kgm

side Pos. 1 side Pos. 2 kN 10

-4

kgm

1 - 0,85 4,21 6 3 4,44

2 - 1,71 8,43 5 4 3,91

3 - 2,56 12,64 7 1 5,60

4 - 3,42 16,86 6 2 4,52

5 - 4,27 21,07 5 3 3,72

6 - 5,12 25,29 4 4 3,42

7 - 5,98 29,50 6 1 4,75

8 - 6,83 33,72 5 2 3,72

9 - 7,68 37,93 4 3 3,08

10 - 8,54 42,14 5 1 3,91

9 1 7,30 4 2 2,96

8 2 6,16 3 3 2,56

7 3 5,19 4 1 3,08

6 4 4,52 3 2 2,26

5 5 4,27 3 1 2,26

8 1 6,44 2 2 1,71

7 2 5,33 2 1 1,48

Adjustment of centrifugal force in facotry 6,16kN

Eccenftric

T00509GB.fm 19

AR 54/3/200/400

Number of Number of Centrifu- Moment Number of Number of Centrifu- Moment

eccentric eccentric gal force inertia eccentric eccentric gal force inertia

weights per weights per weights per weights per

side Pos. 1 side Pos. 2 kN 10

-4

kgm

side Pos. 1 side Pos. 2 kN 10

-4

kgm

1 - 0,59 4,21 7 5 3,70

2 - 1,19 8,43 6 6 3,56

3 - 1,78 12,64 10 1 5,66

4 - 2,37 16,86 9 2 4,85

5 - 2,96 21,07 8 3 4,15

6 - 3,56 25,29 7 4 3,61

7 - 4,15 29,50 6 5 3,30

8 - 4,74 33,72 9 1 5,07

9 - 5,34 37,93 8 2 4,28

10 - 5,93 42,14 7 3 3,61

11 - 6,52 46,36 6 4 3,14

12 - 7,12 50,57 5 5 2,96

13 - 7,71 54,79 8 1 4,48

14 - 8,30 59,00 7 2 3,70

13 17,43 6 33,08

12 26,60 5 42,72

11 35,84 7 13,89

10 45,17 6 23,14

9 5 4,63 5 3 2,58

8 6 4,28 4 4 2,37

7 7 4,15 6 1 3,30

12 16,84 5 22,58

11 26,02 4 32,14

10 35,27 5 12,72

9 4 4,63 4 2 2,05

8 5 4,15 3 3 1,78

7 6 3,89 4 1 2,14

11 16,25 3 21,57

10 25,43 3 11,57

9 3 4,71 2 2 1,19

8 4 4,11 2 1 1,03

Adjustment of centrifugal force in facotry 5,84 kN

Assembly Instructions

SK00003GB.fm 20

8. Assembly Instructions

By all means include washer nr. 0095182 DIN7989-B18

for assembly of external vibrator

Torque setting 210 Nm

for bolts M16 - 8.8

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Wacker Neuson AR 54/3/200/400 User manual

Brand: Wacker Neuson

Model: AR 54/3/200/400

Type: User manual

This manual is also suitable for

AR 54/3,6/460 US

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Wacker Neuson AR 54/3/200/400 User manual

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