Peri VARIOKIT VBC Assembly Instructions Manual

Balanced cantilever hydraulic system, hydraulic system and standard cycle

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VBC Balanced Cantilever Hydraulic System

Hydraulic System and Standard Cycle

Assembly Instructions – Version 2.1

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Page 1 VBC Balanced Cantilever Hydraulic System Hydraulic System and Standard Cycle Assembly Instructions – Version 2.1...
Page 3: Table Of Contents
Content Overview B5 Rear carriage Main components General Activating rear carriage Deactivating the rear carriage Introduction Target groups Operation Product description C1 Drive mode Cleaning and maintenance instructions Moving the balanced cantilever Disposal equipment forward Additional technical documentation C2 Pushing the rail forward Instructions for Use General Preparations...
Page 4: Overview
Overview Main components Top slab formwork Bottom slab formwork Front carriage Rear carriage Front Main Cylinder VBC 280 Driving Cylinder VBC 280 Rear Main Cylinder VBC 280 Lifting and Lowering Cylinder VBC 280 Pre-Tensioning Jack-2 VBC (not shown) Hand Pump-2 VBC (not shown) Rail VBC VBC Balanced Cantilever Hydraulic System – Hydraulic System and Standard Cycle Assembly Instructions...
Page 5: Key
Overview Pictogram | Definition Safety instruction categories Dimensions The safety instructions alert site per- Dimensions are usually given in cm. sonnel to the risks involved and provide Other measurement units, e.g. m, are Danger/Warning/Caution information on how to avoid these shown in the illustrations. risks.
Page 6: Introduction
Qualified personnel complied with! ■ ■ If no country-specific regulations determines measures that provide PERI systems may only be assembled, protection against risks, modified or dismantled by personnel are available, it is recommended to ■ creates a safety and health protec- who are suitably qualified to do so.
Page 7: Product Description
Introduction Product description Intended use These Assembly Instructions Not part of these Assembly PERI products have been designed for describe: Instructions: ■ ■ exclusive use in the industrial and com- Lowering and raising the top and bot- Transport and pre-assembly on the...
Page 8: Cleaning And Maintenance Instructions
Introduction Cleaning and maintenance instructions In order to maintain the value and oper- Spray the rear side of the formwork Internal concrete vibrators should be fit- ational readiness of the formwork ma- with water immediately after concret- ted with rubber caps if possible; as a terials over the long term, clean the ing;...
Page 9: Additional Technical Documentation
Instructions for falling. Assembly and Use is intended as an Operation with damaged or incomplete example. Only PERI original components may be load-carrying equipment is not ■ For use on the construction site, a used. The use of other products and permissible.
Page 10: Safety Instructions
■ Strength class C24 for solid wood ac- arrange for an extraordinary inspec- plied by PERI are available at all times cording to DIN EN 338:2016-07 . tion to be carried out by a competent and understood by the site personnel.
Page 11 Assembly, modification and disman- tling work Every contractor who uses or allows PERI systems may only be assembled, the PERI systems to be used is respon- modified or dismantled under the su- sible for ensuring that the equipment is If personal protective equipment pervision of a person qualified to do so in good condition.
Page 12: System-Specific
Safety instructions System-specific Working areas at great heights are to Secure interim assembly states by be secured by means of appropriate means of temporary supports in order measures to prevent objects from fall- to prevent any items from toppling Safety instructions apply to all ser- ing down.
Page 13 Safety instructions Access Protection against falling Components at risk of structural Safe access to all working areas must components collapse be guaranteed at all times. Work activities may not be carried out Secure components that are likely to simultaneously on areas positioned on become unstable with suitable means, Hatches and openings to accessible top of each other if the lower working...
Page 14 ■ In drive mode, clamping and crushing Only flawless materials may be used. Only PERI original components are hazards are created by moving Have the system checked monthly for to be used for repairs or components.
Page 15: Storage And Transportation
Use original PERI storage and transport systems, e.g. crate pallets, pallets or Do not suspend any objects from the stacking devices. PERI recommends the use of an oil pan electrical lines. to collect hydraulic oil from the hydrau- lic unit. For safe and professional handling of...
Page 16: Component Overview
Component overview Pos. no. Component name Article no. Hydraulic Unit VBC 280 132242 Front Main Cylinder VBC 280 132243 Drive Cylinder VBC 280 132244 Rear Main Cylinder VBC 280 132245 Lifting and Lowering Cylinder VBC 280 132246 Pre-Tensioning Jack-2 VBC 132249 Hand Pump-2 VBC 132250 Rail VBC 128997 Chuck VBC 129660 Cylinder Table VBC Drive Catch Head-2 VBC 134596 Main Frame Chord VBC 129108 Main Frame Post VBC 129100 Rear Carriage Tube VBC 129068 Rear Carriage Rocker VBC 129078 Rear Cylinder Head VBC 129091 Hold-down Bracket VBC 129641 Sliding Plate VBC 129642...
Page 17 VBC Balanced Cantilever Hydraulic System – Hydraulic System and Standard Cycle Assembly Instructions...
Page 18: A1 Storage And Transportation
A1 Storage and transportation Moving on the construction site Transport from and to the construc- Longer storage periods ■ ■ Keep bushing and nipples of all tion site Do not drain the hydraulic oil during ■ quick-couplers clean and fitted with Clean dirt off the hydraulic cylinders downtime.
Page 19: A2 Hydraulic Unit
A2 Hydraulic unit Overview Components 1.10 Hydraulic Unit VBC 280 1.1 Pressure gauge 1.2 Hand valve 1.3 Filling opening for hydraulic oil 1.4 Level and temperature display 1.5 Oil tank 1.6 Oil drain plug 1.7 Oil filter 1.8 Switches with emergen- cy stop function 1.9 Rotary field display 1.10 Mounting frame with attach- ment points for transporta- tion by crane 1.11 Inflow for piston head side 1.12 Return flow for piston rod side 1.13 Bushing for power supply 2-circuit hydraulic system The Hydraulic Unit VBC 280, e.g.
Page 20: A3 Hydraulic System
The hydraulic system is divided into 5 lines as well as “right” and “left” Right valve groups. PERI recommends assigning the con- trol valves in the viewing direction as shown in the illustration. Exception The control valves for cylinders 4R and...
Page 21: Components Used
A3 Hydraulic system Components used As a rule, the following components are used. Take the project-specific documentation into account! Reference Designation Nominal load Area Article Manufacturer (e.g.) Pressing Pulling Piston side Piston rod Type (e.g.) at 280 bar at 280 bar side 1R/1L Front main cylinder...
Page 22: A4 Commissioning
A4 Commissioning Before initial commissioning Electrical connection Further commissioning ■ Connection only by qualified Check the level of the hydraulic oil ■ Check the completeness of the tech- personnel! and top up, if necessary. nical documentation, e.g. hydraulic ■ Check temperature of the hydraulic plan, equipment list, electrical wiring Accessories: oil and, if necessary, bring it up to op-...
Page 23 VBC Balanced Cantilever Hydraulic System – Hydraulic System and Standard Cycle Assembly Instructions...
Page 24: A5 Maintenance
Machine housing (contamination, Monthly to quarterly damage) Performance check Check the entire hydraulic unit (deposits, rust formation). Yearly Reduced interval times PERI recommends shortened mainte- nance intervals: ■ For equipment showing signs of heavy wear. ■ With high thermal and mechanical loads.
Page 25: Hydraulic Oil
A5 Maintenance Hydraulic oil Check oil level Changing hydraulic oil Liquid volume too low ■ Drain hydraulic oil and clean oil tank: the operating temperature increases, ■ air inclusions occur, 1. Completely retract the piston rods. Warning ■ the hydraulic cylinder may extend 2.
Page 26: Replacing Oil Filter
A5 Maintenance Replacing oil filter Filling with new hydraulic oil: 1. Fill tank with hydraulic oil. – Fill tank only up to the top mark- Preparations Assembly ing. Do not overfill! 1. Completely retract all hydraulic cylin- 1. Carefully clean the area around the –...
Page 27: Venting The System
A5 Maintenance Venting the system Flushing and venting the hoses 1. Remove hose covering. In order to ensure error-free operation of the system, the entire system must be bled. This applies in particular to Before every coupling procedure, clean ■ Initial commissioning dirt off the quick-couplers and check for ■...
Page 28: Bleeding The Cylinder
A5 Maintenance Bleeding the cylinder Before starting the bleeding procedure, all hydraulic cylinders must be com- pletely retracted. → If not: connect the hoses to the cylin- der, retract the cylinder completely and then flush the hoses again (see “Flushing and venting the hoses” on 1.
Page 29 A5 Maintenance 7 . Connect the hydraulic hoses to the cylinder. 8. Start the hydraulic unit, operate the hand valve and retract the cylinder completely. → The air pockets on the floor side are displaced. 9. Switch off the hydraulic unit, briefly operate the hand lever and release the pressure in the hose.
Page 30: A6 Remedial Measures For Malfunctions
Remedial measure Cylinder sinks Air in the hydraulic system Vent the system Pressure-retaining valve Replace the cylinder. defective Repairs by PERI Seals defective Replace the cylinder. Repairs by PERI Uneven cylinder extension and Air in the hydraulic system Vent the system...
Page 31 VBC Balanced Cantilever Hydraulic System – Hydraulic System and Standard Cycle Assembly Instructions...
Page 32: Preparation - B2, B3
B1 Overview of the operating sequence General Standard cycle sequence The following operating sequence for moving the balanced cantilever equip- The following working operations are ment describes the standard described in the respective sections. application. Deviations are possible due to proj- Preparation –...
Page 33: B2 Anchoring/Height Adjustment
B2 Anchoring/height adjustment General Pressure conversion Valid for EUROPRESS cylinder CMF60N75 (art. no.: 132249) Height adjustment Pre-tensioning force Pre-tensioning jack pressure The height of the front suspension of [kN] [bar] the slab formwork is adjusted using the pre-tensioning jack and hand pump in the same way as described below.
Page 34: Lowering The Anchoring
B2 Anchoring/height adjustment Lowering the anchoring All illustrations are examples only, other mounting situations are possible. Components 6 Pre-Tensioning Jack-2 VBC 7 Hand Pump-2 VBC 9 Chuck VBC 29 Sliding Plate VBC 62 Domed nut Lowering procedure 1. Place chuck (9), pre-tensioning jack (6) and sliding plate (29a) over the tie rod.
Page 35: Raising The Anchoring
B2 Anchoring/height adjustment Raising the anchoring Components 6 Pre-Tensioning Jack-2 VBC 7 Hand Pump-2 VBC 9 Chuck VBC 29 Sliding Plate VBC 62 Domed Nut D40 Lifting process 1. Place chuck (9), pre-tensioning jack (6) and sliding plate (29a) over the tie rod. 2. Screw domed nut (62a) onto the tie rod until it rests against the sliding plate (29).
Page 36: B3 Bottom Slab Formwork
B3 Bottom slab formwork General information Warning Incorrect operation or hydraulic damage can cause unforeseen movements of the components. As a result, body parts could become trapped and crushed. ⇒ While the tie nut is being screwed in, no other work is to be carried out on the machine.
Page 37 B3 Bottom slab formwork ■ Carry out the lowering procedure on all 4 suspensions at the same time. ■ Maintain constant contact with the operator of the hydraulic unit during the lowering process. Lowering procedure 1. Raise the upper tie nut (61a) by < 25 cm.
Page 38: Raising The Bottom Slab Formwork
B3 Bottom slab formwork Raising the bottom slab formwork Components 5 Lifting and Lowering Cylinder VBC 280 10 Cylinder Table VBC 35 Lifting Counterplate VBC 61 Tie nut straight ■ Carry out the lifting procedure on all 4 suspensions at the same time. ■ Maintain constant contact with the operator of the hydraulic unit during the lifting process.
Page 39 VBC Balanced Cantilever Hydraulic System – Hydraulic System and Standard Cycle Assembly Instructions...
Page 40: B4 Front Carriage
B4 Front carriage General If the front carriage is deacti- Warning vated, place the front main cylinder in a load-free posi- Incorrect operation or hydraulic damage tion, remove bolts at the top can cause unforeseen machine and completely retract. As a movements.
Page 41: Activating Front Carriage
B4 Front carriage Activating front carriage → Carriage is in a supported position = operational mode. → Brake is activated. 1. Extend the front main cylinder (2). → Front carriage (31) moves down- wards until the roller bearing (31.1) is positioned on the rail (8).
Page 42: Deactivating Front Carriage
B4 Front carriage Deactivating front carriage → Carriage is in a raised position = drive mode. 1. Retract the front main cylinder (2). → The front main cylinder lowers the main frame post (24) until the post base (30) rests on the structure. (Fig. B4.06 + B4.07) →...
Page 43 VBC Balanced Cantilever Hydraulic System – Hydraulic System and Standard Cycle Assembly Instructions...
Page 44: B5 Rear Carriage
B5 Rear carriage General Components: 4 Rear Main Cylinder VBC 280 Danger 8 Rail VBC The rear carriage as well as the rail are 23 Main Frame Chord VBC subjected to high lifting forces. 25 Rear Carriage Tube VBC If connecting elements are improperly 26 Rear Carriage Rocker VBC released, this can lead to sudden lifting 27 Rear Cylinder Head VBC of the rear carriage or rail and cause the 28 Hold-down Bracket VBC...
Page 45: Activating Rear Carriage
B5 Rear carriage Activating rear carriage → Carriage is in an anchored position = operational mode. Force progression during operation The lifting forces from the main frame chord (23) are transferred to the main tie rod (53) via the main tie nut (63b). At the yoke pin (26.1), the force is transferred to the rear carriage rocker (26).
Page 46 B5 Rear carriage Step 2 1. Extend the rear main cylinder (4) approx. 50 mm. → The rear cylinder head (27) is pressed upwards and pulls the roll- er blocks (36) against the rail (8). → The rear carriage tube (25) is pressed downwards with the rear carriage rocker (26) against the lift- ing force.
Page 47 B5 Rear carriage Step 3 1. Release the upper domed nuts (62). 2. Screw out the upper anchor tie rods (52) from the hexagonal coupler (64) and lay to one side. 3. Remove the hexagonal coupler and lay to one side. (Fig. B5.03) Fig. B5.03 VBC Balanced Cantilever Hydraulic System –...
Page 48 B5 Rear carriage Step 4 1. Loosen the bottom auxiliary tie nuts (61a) and screw upwards approx. 10 cm. 2. Retract the rear main cylinder (4). → The rear cylinder head (27) is held in position through the auxiliary tie rods (51) and roller blocks (36). →...
Page 49: Deactivating The Rear Carriage
B5 Rear carriage Deactivating the rear carriage → The carriage is in drive mode. → The carriage is centred over the an- choring and hold-down brackets. Force progression in drive mode See “Step 4” on page 48. Step 1 1. Loosen the main tie nut (63) in order to create space.
Page 50 B5 Rear carriage Step 3 1. Screw the hexagonal coupler (64) onto the bottom anchor tie rods (52a) up to the middle of the coupler. 2. Insert top anchor tie rods (52b) through the rear carriage rocker (26) and screw firmly into the hexagonal coupler.
Page 51 B5 Rear carriage Step 4 1. Loosen the bottom auxiliary tie nuts (61b) and screw upwards approx. 10 cm. 2. Retract the rear main cylinder (4). → Anchor tie rods (52) are subject to tensile stress and keep the ma- chine operational. →...
Page 52: C1 Drive Mode
C1 Drive mode General Components: 3 Driving cylinder 8 Rail VBC 21 Drive Catch Head-2 VBC The balanced cantilever equipment is always moved or locked in a controlled manner by two independent drive catch heads (21). The two drive catch heads are identical in construction and function. The drive catch head (21B) is mounted to the main frame column with the cou- pling rod (21.3).
Page 53: Moving The Balanced Cantilever Equipment Forward
C1 Drive mode Moving the balanced cantile- ver equipment forward Requirements ■ Driving cylinder is retracted. ■ Locking plates of both drive catch heads are engaged in a section of the rail. ■ The entire unit has been put into drive mode: –...
Page 54 C1 Drive mode 4. Press the release lever (21.2) of the drive catch head (21A) downwards, thereby lifting the locking plate (21.1). (Fig. C1.05) 21.2 21.1 Fig. C1.05 5. Retract the drive cylinder (3) to the next section of rail (8.1). After leaving the previous section of rail, the re- lease lever can then be released.
Page 55 C1 Drive mode → The locking plate (21.1) of the drive catch head (21A) drops into the next section (8.1) of the rail. (Fig. C1.07) 6. Stop the drive cylinder from retract- ing any further. 7 . Repeat steps 1 to 6 until the bal- anced cantilever equipment has reached the next concreting section.
Page 56: C2 Pushing The Rail Forward
C2 Pushing the rail forward General Preparations 1. On the rear carriage, release the hold-down brackets (28) of the rail. Danger To do this, loosen the bottom domed The rear carriage as well as the rail are nuts (62a) on the bottom anchor tie subjected to high lifting forces.
Page 57 C2 Pushing the rail forward 3. On the front carriage, release the hold-down bracket from the rail. For this, loosen the domed nut on the anchor tie rod and turn the hold- down bracket to the side. 4. Raise the front carriage. To do this, retract the front main cylinder (2), thereby pulling the shoe side guide (37) of the front carriage (31) up...
Page 58: Pushing The Rail Forward
C2 Pushing the rail forward Pushing the rail forward Components: 3 Driving cylinder 8 Rail VBC 21 Drive Catch Head-2 VBC 21.2 Requirements 21.1 ■ Driving cylinder is retracted. ■ Locking plates of both drive catch heads are engaged in a section of the rail. Drive mode 1.
Page 59 C2 Pushing the rail forward → The locking plate (21.1) drops into the previous section (8.1) of the rail. 3. Stop the drive cylinder from extend- ing any further. (Fig. C2.06) 21.1 Fig. C2.06 4. Press the release lever (21.2) on the drive catch head (21B) downwards, thereby lifting the locking plate (21.1).
Page 60: Subsequent Work
C2 Pushing the rail forward → The locking plate (21.1) of the drive catch head (21B) drops into the next section (8.1) of the rail. 6. Stop the drive cylinder from retract- ing any further. (Fig. C2.08) 7 . Repeat steps 1 and 6 until the rail has reached its designated position.
Page 61 VBC Balanced Cantilever Hydraulic System – Hydraulic System and Standard Cycle Assembly Instructions...
Page 62: Appendix
Die Inbetriebnahme unseres Produktes bleibt so lange untersagt, bis festgestellt wurde, dass die Ausführung der Anlage/ Maschine, in welcher der Einbau erfolgen soll oder von dem es ein Teil sein wird, mit den entsprechenden Rechtsvorschriften übereinstimmt. Bevollmächtigter für die Zusammenstellung PERI SE, GROUP QUALITY der technischen Unterlagen: Anschrift siehe Hersteller Hiermit erklären wir, dass die Bauart und die Ausführung...
Page 63 The commissioning of our product remains prohibited until it has been determined that the design of the system/machine in which it is to be installed or of which it will be a part complies with the relevant legal regulations. Person established in the Community authorized PERI SE, GROUP QUALITY to compile the relevant technical documentation: Address, see manufacturer...
Page 64: Hydraulics Vbc
Hydraulics VBC Art no. Weight [kg] 316.000 Hydraulic Set 1 VBC 280 132256 Consisting of: 2 pc. 132243 (65,3kg) Front Main Cylinder VBC 280 2 pc. 132244 (74,3kg) Drive Cylinder VBC 280 1 pc. 132252 (36,4kg) Transport Box Hydraulic Set-1 VBC 1200 Art no.
Page 65 Hydraulics VBC Art no. Weight [kg] 0.850 Return Filter Pump VBC 280 133758 Spare oil filter for the Hydraulic Pump VBC 280. Ø Art no. Weight [kg] 132247 0.944 Powercable VBC 280 CEE-16A-200 For connecting the Hydraulic Pump VBC to the power supply system. Notes With CEE socket 400 V, 16 A with manual phase inverter.
Page 66 137373 18.300 Hydr.Oil ISO11158 HVI32 20l 057376 18.300 Hydr.Oil ISO11158 HVI46 20l High-quality synthetic hydraulic oils for PERI Hydraulic Power Units with different viscosity suitable for certain temperature ranges. Notes Filter with filter pump before filling the aggregates. Observe Safety Data Sheet and applicable National Safety Regulations regarding hydraulic oil, in particular for transport, storage and disposal! Observe the technical documentation for the hydraulic power unit! Product Data Sheet on request.
Page 67 Hydraulics VBC Art no. Weight [kg] 14.000 Hydr.Oil Filter Pump CE 137281 Filter pump for quick and clean transfer of hydraulic oil with simultaneous filtration. Notes Follow Instructions for Use! Power connection 220V/50Hz, plug CEE 7/7 Accessory (not included) 137282 1.000 Hydr.Oil Filterelement 500 137283 1.000 Suction-/Pressure Hose 250...
Page 68 Hydraulics VBC Art no. Weight [kg] L [mm] X [mm] Hydr.Hoses 853-2SN-DN08-FF 129035 0.996 Hydr.Hose 853-2SN-DN08-FF 1m 1169 1000 129036 1.430 Hydr.Hose 853-2SN-DN08-FF 2m 2169 2000 129419 2.690 Hydr.Hose 853-2SN-DN08-FF 5m 5170 5000 129420 4.900 Hydr.Hose 853-2SN-DN08-FF 10m 10170 10000 129421 7 .120 Hydr.Hose 853-2SN-DN08-FF 15m 15170 15000...
Page 69 Hydraulics VBC Art no. Weight [kg] 1.370 Hydr.T-Piece 2SN-DN08-FF 129423 1222 Consists of 1 pc 128992 Pin ISO16028 DN10 R3/8IG 2 pc 128993 Sleeve ISO16028 DN10 R3/8IG 3 pc 051750 Male STUD Coupl. X-GE12PSR-ED Art no. Weight [kg] 112421 3.000 Hydr. Accum. Piece RCS To double the volume of the oil at the Hydraulic Pump RCS.
Page 70 Hydraulics VBC Art no. Weight [kg] 0.440 FF-Coupling Pair X-GE12PSR-ED+ 129424 Spare parts set for PERI Hydraulic Components with quick couplings X-GE 12PSR-ED+. Notes For assembling on hydraulic hoses EN853-2SN-DN08. M 20x1,5 SW 27 SW 22 G 3/8 G 3/8...
Page 71 1 pc. 135174 Allen Key SHR-Bit SW06 1 pc. 135175 Allen Key SHR-Bit SW08 1 pc. 135176 Allen Key SHR-Bit SW10 1 pc. 135177 SHR Screwdriver Bit 6 parts Slot/PH 2 pc. 711035 PERI Label 128x65mm 1 pc. 126434 List of contents Hydraulic Service Case...
Page 72 Slab formwork Climbing systems Bridge formwork Tunnel formwork Shoring systems Construction scaffolds Façade scaffolds Industrial scaffolds Access Safety scaffolds Safety systems System-independent accessories Services PERI Danmark A/S Forskalling & Stilladssystemer Greve Main 26 2670 Greve Tlf. +45 4345.3627 peri@peri.dk www.peri.dk...

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Vbc 280