Operator's manual Internal vibrator IRflex FUflex Model IRflex, FUflex Document 5100032233 Issue 11.
Copyright © 2018 Wacker Neuson Produktion GmbH & Co. KG Printed in Germany All rights are reserved, in particular the worldwide applicable copyright, right of duplication and right of distribution. This document may only be used by the recipient for the intended purpose. The document may not be reproduced entirely or partially, or translated into any other language. Reproduction or translation, even extracts thereof, only with written approval of Wacker Neuson Produktion GmbH & Co. KG.
1 CALIFORNIA Proposition 65 Warning 1 CALIFORNIA Proposition 65 Warning WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. WARNING Cancer and Reproductive Harm www.P65Warnings.ca.gov.
1 CALIFORNIA Proposition 65 Warning 4 100_0000_0024.
Table of contents 1 CALIFORNIA Proposition 65 Warning .................................................................................3 2 Preface ....................................................................................................................................7 3 Introduction ............................................................................................................................8 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 4 Using the manual.............................
Table of contents 12.2 Maintenance jobs....................................................................................................................... 28 13 Faults .................................................................................................................................... 30 13.1 Troubleshooting table - FUflex Inverter ..................................................................................... 30 13.2 Troubleshooting Table - Bodyguard®.............................
2 Preface 2 Preface This operator's manual contains important information and procedures for the safe, proper and economic operation of this Wacker Neuson machine. Carefully reading, understanding and observing is an aid to avoiding hazards, repair costs and downtime, and therefore to increasing the availability and service life of the machine. This operator's manual is not a manual for extensive maintenance or repair work.
3 Introduction 3 3.1 Introduction Using the manual This manual is to be considered part of the machine and should be carefully stored during the entire service life of the machine. This manual shall be transferred to subsequent owners or users of the machine. 3.2 Storage location of the manual This manual is part of the machine and must be kept in the immediate vicinity of the machine and made accessible to staff at all times.
3 Introduction NOTICE Supplementary information. 3.7 Wacker Neuson Contact partner Depending on the country, the Wacker Neuson contact partner is a Wacker Neuson service department, a Wacker Neuson subsidiary, or a Wacker Neuson dealer. On the Internet at www.wackerneuson.com. 3.8 Disclaimer For the following violations, Wacker Neuson dismisses any liability for personal injury or material damage: 3.9 Failure to follow this manual. Unintended use. Deployment of untrained personnel.
4 Security 4 Security NOTICE Read and comply with all notes and safety instructions in this manual. Failure to comply with these instructions can cause electric shock, fire and/or serious injuries as well as damage to the machine and/or damage to other objects. Keep safety instructions and notes for the future. 4.1 Policy In keeping with the latest technological developments The machine has been built in keeping with the latest technological developments and the recognized technical safety rules.
4 Security 4.4 Use a risk assessment to identify the dangers that result from the working conditions at the site of application. Create operating instructions for the operation of this machine. Periodically check whether the user instructions correspond to the current state of regulations. Clearly regulate and specify responsibilities for operation, troubleshooting, maintenance, and cleaning. Regularly train employees and inform them about potential hazards.
4 Security 4.6.4 In the case of extensive work with this machine, long-term vibration-induced damage cannot be ruled out. For exact values of vibration measurement, refer to the Technical Data section. Wear suitable clothing. Keep loose clothing, gloves, jewelry, and long hair away from moving/rotating machine parts. Danger of being pulled! Ensure that no other individuals are in the danger zone! Handling and use Handle machines with care.
4 Security 4.9 Do not use the protection hose, power cable or other components of the machine as a climbing aid or to secure transport. Vibration-induced long-term damage cannot be ruled out during intensive use of hand-operated machinery. The respective statutory provisions and guidelines shall be observed. The vibration emission value may differ from the declared value depending on the nature and manner in which the power tool is used.
4 Security 4.11 Safety devices Safety devices protect the user of this machine from being exposed to existing hazards. These are barriers (separating protective devices) or other technical measures. This prevents the user from being exposed to a danger. The source of danger will be eliminated in certain situations or the danger will be reduced. This machine has the following safety equipment: 1 Item Description 1 Bodyguard® Bodyguard® The Bodyguard® acts to protect the operator from electric shock.
5 General safety instructions for power tools 5 General safety instructions for power tools WARNING Read all safety warnings, instructions, illustrations and specifications provided with this power tool. Failure to follow all instructions listed below may result in electic shock, fire and/or serious injury. Save all warnings and instructions for future reference. The term "power tool" in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool. 1.
5 General safety instructions for power tools a) Do not force the power tool.Use the correct power tool for your application. The correct power tool will do the job better and safer at the rate for which it was designed. b) Do not use the power tool if the switch does not turn it on and off. Any power tool that cannot be controlled with the switch is dangerous and must be repaired.
6 Safety and information labels 6 Safety and information labels WARNING Illegible symbols Over time, labels and signs on the machines can become dirty or otherwise unrecognizable. Keep all safety, warning, and operating instructions on the machine in a legible condition. Replace damaged labels and signs immediately. The following labels are found on the FUflex inverter: IRflex FUflex 1, 2, 3 Item Label Description 1 0219413 2 3 US-machine Attention: electric shock.
7 Setup and function 7 7.1 Setup and function Standard package The standard package includes: IRflex vibrator head (optional). FUflex inverter (optional). Operator's manual. NOTICE The components, that are marked as optional must be ordered separately. The IRFUflex machine consists of two components: 7.2 IRflex vibrator head. FUflex inverter. Application areas The internal vibrator is a machine used to de-aerate and compact freshly mixed (green) concrete. 7.
8 Components and operator's controls 8 8.1 Components and operator's controls Components These components can be combined in different designs, depending on the application conditions.
9 Quickflex Coupling Assembly 9 Quickflex Coupling Assembly As needed, the Quickflex coupling enables the exchange of the IRflex vibrator head. This can thus be exchanged for a new or different vibrator head with various sized diameters and protective hose lengths. 9.
9 Quickflex Coupling Assembly 9.3 Assemble IRflex vibrator head and FUflex inverter 2 1 Item Designation Item 1 FUflex inverter 2 Quickflex coupling, Locking nut (IR side)/ coupling thread(FUflex side) 3 3 Designation IRflex vibrator head 1. Clean the flat-faced sealing surfaces of the Quickflex coupling and inspect for damage. NOTICE The flat-faced sealing surfaces of the Quickflex coupling are soft components, which are co-responsible for IP protection.
9 Quickflex Coupling Assembly 4. Tighten the retaining screw using the Allen wrench. NOTICE The retaining screw must be completely screwed in, otherwise there is a danger the machine will remain stuck during operation, e.g. on a reinforcement. 5. Press protective cap onto the retaining screw. 22 100_0101_ot_0003.
10 IRFUflex Transport 10 IRFUflex Transport WARNING Improper handling may result in injury or serious material damage. Please read and follow all safety instructions in this operator's manual. WARNING Hot vibrator head. Contact may cause burns. 10.1 Allow vibrator head to cool down. Wear protective gloves. Loading and transport Carry out preparations 1. 2. 3. 4. 5. Switch the equipment off with the ON/OFF switch. Wait until the machine has come to a complete standstill.
11 Operation and use 11 Operation and use WARNING Improper handling may result in injury or serious material damage. Read and observe all safety instructions in this operator's manual, see chapter Safety. WARNING Leak current due to moisture penetration. Injury from electric shock. 11.1 Use the extension cable in IPx4 design so that the connection link of the plug / coupling is splash-water protected.
11 Operation and use WARNING Electrical voltage. Injury from electric shock. Check power cable and extension cable for damage. Only use extension cables whose grounded conductor is connected to the plug and coupling (only for machines of class rating I, see chapter Technical data). WARNING Machine start-up. Risk of injury from uncontrolled start-up of machine. Switch the machine off before connecting to the electric power supply. 1. Switch the machine off with the ON/OFF switch. 2.
11 Operation and use 11.4.1 Compacting freshly mixed (green) concrete 1. Hold the machine with both hands on the protection hose and guide it. 2. Quickly immerse, submerge the vibrator head into the freshly mixed (green) concrete, wait for a few seconds and slowly pull it out. 3. Immerse the vibrator head in all areas of the formwork and compact the freshly mixed (green) concrete.
11 Operation and use 1. 2. 3. 4. Slowly pull the vibrator head out of the freshly mixed (green) concrete and hold it in the air. Switch the machine off with the ON/OFF switch. Wait until the machine has come to a complete standstill. Slowly set machine down. NOTICE Do not bend the protection hose and power cable. 5. Pull the plug out of the plug receptacle. 6. Let the machine cool. 11.6 After operation 11.6.1 Clean the machine Clean all components after each operation.
12 Maintenance 12 Maintenance WARNING Improper handling may result in injury or serious material damage. Please read and follow all safety instructions in this operator's manual. WARNING Risk of death from electric shock in the event of improper work. 12.1 According to the applicable guidelines, opening the machine, repairing and a subsequent safety control may only be performed by a qualified electrician.
12 Maintenance 12.2.1 Visual inspection for damage and leaks WARNING Damage to the machine or power cable can lead to physical injury from electric shock. Check all components for damage. Check the seal of the switch membrane of the on/off switch against leakage. Check the flat-faced sealing surfaces/soft components of the Quickflex coupling for damage and impurities. 12.2.2 Do not operate a damaged machine. Have damaged machine repaired immediately.
13 Faults 13 Faults DANGER Danger to life from unauthorized troubleshooting. 13.1 If faults occur with this machine that are not described in this manual, contact the manufacturer. Do not eliminate the faults independently. Troubleshooting table - FUflex Inverter Fault Cause The control lamp illuminates red. Mains voltage interrupted. Incorrect mains voltage. Remedial measure The inverter starts automatically as soon as the correct mains voltage is present (again).
14 Disposal 14 Disposal 14.1 Disposal of old electrical and electronic equipment Professional disposal of this machine avoids negative effects on human health and the environment, helps with the targeted treatment of pollutants and makes it possible to recycle valuable raw materials. For customers in EU countries This machine is subject to the European directive for old electrical and electronic equipment (Waste Electrical and Electronic Equipment (WEEE)), as well as the corresponding national laws.
15 Technical data 15 Technical data 15.1 IIRflex38 US Designation Unit Item number IRflex38/120/3 US IRflex38/120/5 US 5100034275 5100025583 Rated current A 1.70 1.
15 Technical data 15.2 IRflex45 US Designation Unit Item number IRflex45/120/5 US 5100025587 Rated current A 2.50 Rated voltage V 220 Rated frequency Hz 200 Rated power** kW 0.58 Phases ~ Double amplitude of play mm Oscillations 1/min 3 2.3 12,000 Hz 200 Overheat protection triggering °C 150 Vibrating body diameter mm 45 Protection hose external diameter mm 31 Length of vibrator head mm 382 Length of protection hose m 5 Weight kg 8.
15 Technical data 15.3 IRflex58 US Designation Unit Item number IRflex58/120/5 US IRflex58/120/8 US IRflex58/120/ 10 US IRflex58/ 120/15 US 5100025591 5100034276 5100025592 5100038507 Rated current A 3.30 3.30 3.30 3,30 Rated voltage V 220 220 220 220 Rated frequency Hz 200 200 200 200 Rated power** kW 1.05 1.05 1.05 1,05 Phases ~ 3 3 3 3 Double amplitude of play mm 2.5 2.5 2.5 2,5 Oscillations 1/min 12,000 12,000 12,000 12.
15 Technical data 15.4 IRflex60 US Designation Unit Item number IRflex60/120/5hr US IRflex60/120/10hr US 5100034273 5100034274 Rated current A 3.30 3.30 Rated voltage V 220 220 Rated frequency Hz 200 200 Rated power** kW 1.05 1.05 Phases ~ 3 3 Double amplitude of play mm 2.4 2.4 Oscillations 1/min 12.000 12.
16 Technical data 16 Technical data 16.1 FUflex US Designation Unit Item number FUflex4/120 US 5100025403 Rated current A 12.00 Rated voltage V 120 Rated frequency Hz 50 – 60 Electrical load rating kVA 1,44 Phases ~ 1 Output current A 3.5 Output voltage V 220 Output frequency Hz 200 Output rated power kVA 1,33 Output phases ~ Length mm 350 Width mm 90 Height mm 100 Length of power cable* m 15 Weight kg 9.
16 Technical data 16.1.1 Extension cable WARNING Electrical voltage. Injury from electric shock. Check power cable and extension cable for damage. Only use extension cables whose grounded conductor is connected to the plug and coupling (only for machines of class rating I, see chapter Technical data). Only use approved extension cables, see chapter Safety.
16 Technical data Machine Voltage [V] Extension [m] Cross-section area of cable [AWG] IRFUflex58 US 120 1~ < 59 14 < 93 12 < 148 10 < 51 14 < 80 12 < 126 10 IRFUflex60hr US 38 120 1~ 100_0101_td_0025.
17 Glossary 17 Glossary Class rating The class rating according to DIN EN 61140 identifies electrical machines in terms of safety measures for the prevention of an electric shock. There are four class ratings: Class rating Significance 0 No special protection, other than the basic insulation. No grounded conductor. Plug connection without a grounded conductor contact. I Connection of all conductive housing components to the grounded conductor. Plug connection with a grounded conductor contact.
EC Declaration of Conformity Manufacturer Wacker Neuson Produktion GmbH & Co. KG, Wackerstraße 6, D-85084 Reichertshofen This declaration of conformity is issued under the sole responsibility of the manufacturer.
EC Declaration of Conformity Manufacturer Wacker Neuson Produktion GmbH & Co. KG, Wackerstraße 6, D-85084 Reichertshofen This declaration of conformity is issued under the sole responsibility of the manufacturer.
