Wacker Neuson AR 75/3/200/400 User manual

Operator´s Manual
EXTERNAL VIBRATORS
AR 75
0203468en 005
12.2009

Manufacturer
Wacker Neuson SE
Preußenstraße 41
80809 München
www.wackerneuson.com
Tel.: [phone]
Fax: [phone]
Translation of the original operator’s manual in German

1Foreword
1Foreword
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.
All rights reserved, especially reproduction and distribution rights.
Copyright 2009 Wacker Neuson SE
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
4
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 15
4.1 Operating range ..................................................................................15
4.2 Description of function .........................................................................15
4.3 Note .....................................................................................................15
4.4 Connection ..........................................................................................15
4.5 Wiring diagram ....................................................................................16
5. Maintenance 18
5.1 Motor casing ........................................................................................18
5.2 Maintenance schedule ........................................................................18
6. Diagram 19
7. Eccenftric 20
8. Assembly Instructions 23
9. Labels 24
10. Disposal 25
10.1 Environmentally friendly reuse ............................................................25
Declaration by the manufacturer 27
DIN EN ISO 9001 Certificate 29

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
TD00417GB.fm 13
3. Technical data
AR 75/3/200/
400
AR 75/3/230/
400
AR 75/3,6/230/
400
AR 75/3,6/220/
440
Item no. 0007900 0007898 0007899 0007951
Length x width x height
mm: 330 x 218 x
218
420 x 218 x
218 330 x 218 x 218
Operating weight
kg: 30,7 31,4 29,3
Drive High-frequency squirrel-cage induction motor to be connected up with
frequency and voltage transformer
Voltage
V: 200/400 230/400 220/440
Frequency
Hz: 50 60
Rated current
A: 4,8/2,4 4,2/2,4 4,4/2,2
Vibrations
min-1:3000 3600
Centrifugal force
kN: 17,25 19,91 17,2
Type of protection IP65
Sound pressure level LPA
at operator’s station
dB (A):
70
The sound value was determined according to EN ISO 11204 for sound pressure levels (LpA), at
nominal motor rpm's and while freely hanging in the air.

Technical data
TD00417GB.fm 14
AR 75/3,6/460 AR 75/3,6/318/
550
Item no. 0007889 0007943
Length x width x height
mm: 330 x 218 x 218
Operating weight
kg: 29,3
Drive High-frequency squirrel-cage induction motor to be connected up with
frequency and voltage transformer
Voltage
V: 230/460 318/550
Frequency
Hz: 60
Rated current
A: 4,2/2,1 3,1/1,8
Vibrations
min-1:3600
Centrifugal force
kN: 17,2
Type of protection IP65
Sound pressure level LPA
at operator’s station
dB (A):
70
The sound value was determined according to EN ISO 11204 for sound pressure levels (LpA), at
nominal motor rpm's and while freely hanging in the air.

Description
T00575GB.fm 15
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 from 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. By all means
include washer DIN7989 - B18 for assembly of external vibrator. (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 75/3/200/400
AR 75/3,6/220/440
AR 75/3,6/460
AR 75/3/230/400
AR 75/3/240/415
AR 75/3,6/230/400
AR 75/3,6/318/550
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
T00575GB.fm 16
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

Description
T00575GB.fm 17
Vast voltage 400/415/550 V
black
blue
brown
green/yellow
Normal voltage 230/240/318 V
black
blue
brown
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
T00552GB.fm 18
5. Maintenance
5.1 Motor casing
The bearings of the external vibrator can be lubricated from the
outside. Remove closure screws (1) from motor casing. Grease with
appropriate grease gun. Screw closure screws (1) back in again.
5.2 Maintenance schedule
Parts Maintenance Jobs Maintenance intervals
Supply cable Check for perfect condition:
replace defective cable. daily
External vibrator Retighten all accessible screw
connections. after first 20 hours
Motor casing Lubricate. (Unirex N2) 200 hours

Diagram
SK00001GB.fm 19
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 mm2
Cross section as per table: 15 A : 1mm2
Chosen cross section: 2,5 mm2
Voltage - Frequency - Curves
Cross-section area of cable in mm2Minimum cross-section
area according to VDE
Max. Max.
Cable load fuse
mm2AA
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
T00576GB.fm 20
7. Eccenftric
AR 75/3/ AR 75/3/ AR 75/3,6/ AR 75/3,6/...
200/400 230/400 220/440
Flywheel No. 0034698 0034698 0034698 0034698
Quantity per machine 26 30 18 18
External diameter (D) 163 163 163 163
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 120oto 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 75/3,6/220/440; AR 75/3,6/460
Number of Number of Centri- Moment of Number of Number of Centri- Moment of
eccentric eccentric fugal inertia eccentric eccentric fugal inertia
weights per weights per weights per weights per
side Pos. 1 side Pos. 2 kN 10-4 kgm2side Pos. 1 side Pos. 2 kN 10-4 kgm2
1 - 1,91 11,37 5 3 8,33
2 - 3,82 22,74 4 4 7,65
3 - 5,73 34,12 6 1 10,64
4 - 7,65 45,49 5 2 8,33
5 - 9,56 56,86 4 3 6,89
6 - 11,47 68,23 5 1 8,76
7 - 13,38 79,61 4 2 6,62
8 - 15,29 90,98 3 3 5,73
9 - 17,20 102,35 4 1 6,89
8 1 14,43 3 2 5,06
7 2 11,94 3 1 5,06
6 3 9,93 2 2 3,82
5 4 8,76 2 1 3,31
7 1 12,53 1 1 1,91
6210,11
Adjustment of centrifugal force in factory 11,94 kN