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DYNAPAC AT/AHS

HIGH FREQUENCY
POKER VIBRATORS

INSTRUCTIONS&SPARE PARTS CATALOGUE AT/AHS - IS - 10540 - 1 -


ENG
SAFETY INSTRUCTIONS

- MACHINES SUBMITTED : Powered with : Electric, Pneumatic, Petrol or Diesel engine.

- SYMBOLS : The words WARNING and CAUTION used in safety instructions, have the following
meanings :
WARNING indicates hazards or hazardous procedures which could result in serious injury or death,
if the WARNING is not observed.
CAUTION indicates hazards or hazardous procedures which could result in injury or damage to
equipment if the WARNING is not observed.

- IMPORTANT RULES FOR YOUR SAFETY :

WARNING

The machine must not be modified without prior consent of the manufacturer. Use only original parts. If
modifications are made without prior consent of the manufacturer there is a risk of serious injury to the personal.

- These safety recommendations have been compiled from international safety standards.
Local regulations must also be checked and observed. Before using the machine, read carefully these
instructions and keep them in a safe place.
- Make sure that the signs about using, safety, and maintenance are always legible.
- The use of the machine is restricted to the applications specified in the product litterature.
- Always change damaged parts immediately. Change wear parts in due time.

- SAFETY EQUIPMENT :
WARNING

The admissible sound level of 85 dB (A), can be exceeded because of the machine and/or the application. Long time
exposure to loud noise without ear protectors can cause permanent damage to hearing.
Long time exposure to vibrations can damage the hands, fingers and wrists. Do not use the machine if you are
experiencing discomfort, cramp or pain. Consult a doctor before working again with the machine.

- Always use approved safety equipment. The following safety equipment applies to operators and other
personnel in the immediate vicinity of the working zone.
- Safety helmet.
- Ear protectors.
- Dust mask in dusty environments.
- Protective gloves.
- Protective shoes.
- Goggles.

To avoid the risk of clothes being caught in the machine, avoid wearing loose-lifting clothes. If you have long hair, cover
it with a hair net.

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- WORKING AREA :

WARNING

Do not use the machine in explosive environments.


Do not operate a machine powered by a petrol or diesel engine in poorly ventilated spaces. These types of engines
produce toxic gases which can cause serious health troubles.
- POWER SUPPLY :

WARNING

Make sure that the power supply equipment complies with the relevant safety requirements of the local and the
international standards.

- Electric machine : It must be ensured that the machine is connected to the voltage and the frequency
specified on the name plate. The power supply cable has to be properly sized. Check that the cable and the plug of the
machine are not damaged. Never switch off the machine by pulling the plug from its socket. Use the machine switch.
Keep the cable out of the moving parts of the machine.

- Pneumatic machine : Check that the compressed-air hose and the hose coupling are not damaged. Never
attempt to loosen a compressed-air hose which is pressurized. First switch off the air at the compressor and then leave
the machine running itself to discharge the hose after some seconds.

- Machine powered by petrol or diesel engine : Petrol has an extremely low flash-point and can be explosive in
certain situations. Keep away from all hot or spark-generating objects, do not smoke, when handling fuel. Wait until the
machine has cooled before filling the tank. Avoid spilling petrol or diesel on the ground.

- STARTING THE MACHINE :

CAUTION

Before starting make yourself familiar with the machine and make sure that the machine does not show any obvious
faults. Then start the machine according the instruction and spare parts catalogue.

- OPERATION :

CAUTION

Use the machine only for the purpose for which it is intended. Make sure you know how to stop the machine quickly
in the event of an emergency situation. Do not touch rotating parts during operation.

- MAINTENANCE :

CAUTION

Maintenance work must only be carried out by skilled personnel. Keep unauthorized persons away from the machine.
Do not carry out maintenance work while the machine is moving or the engine is running. Never use a machine which
is damaged.

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- BE ALERT :

CAUTION

Always concentrate on what you are doing. Use common sense. Never operate the machine if you are tired or under
the influence of drugs alcohol or other substances which can affect your vision, reaction, ability or judgement.

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GENERAL

The high frequency poker vibrators combine 3 units : Vibrator tube, flexible shaft and drive unit in order to get a complete
machine for concrete vibration applications. The system includes :
- 2 electric drive units type AH15S, AH25S single phase motors.
- 5 flexible shafts available in following sizes :1m, 1,5m , 2m , 3m , 4m.
- 4 pokers available in following sizes : AT29 , AT39 , AT49 , AT59.

DESIGN

The drive units AH15S an AH25S , have an ergonomic design and feature a steel-chromed sturdy frame with large
rubbershock-absorbers. They are double-insulated and splash-proof. Flexible shafts can be connected with press-button
simplicity, without having to screw. An optional carrying strap is available for operator's comfort.
- High quality flexible shafts SUPERFLEX are oil-resistant and protected by a reinforced steel armature.
- The poker vibrators are made of high-wear steel and feature hardened housing with life-time lubricated
bearings.
- Adapters to fit previous version of AH and flexible shafts on the new version are available.

TECHNICAL DATA

ELECTRICAL DRIVE UNIT AH15S/AH25S


TECHNICAL DATA AH15S AH15S AH25S AH25S
P/N 362589 P/N 362534 P/N 362590 P/N 362535
Voltage (V) 115 230 115 230
Input kW - (Hp) 1 - (1 3/8 ) 1 - (1 3/8 ) 1.60 - (2 1/4 ) 1.60 - (2 1/4 )
Phase 1 1 1 1
Frequency (Hz) 50/60 50/60 50/60 50/60
Current (A) 9.20 4.80 14.70 7.60
Speed at full load (rpm) 12 000 12 000 12 000 12 000
Noise level measured in air driving one AT
49 with 4m flexible shaft , at1 m from the 75.00 75.00 84.00 84.00
poker dB(A), according to ISO 6081.
Weighted effective acceleration AT 29 : 5.56 AT 29 : 5.56 AT 29 : 5.56 AT 29 : 5.56
measured in air driving one poker, on the AT 39 : 6.22 AT 39 : 6.22 AT 39 : 6.22 AT 39 : 6.22
hose, at 1m from the end of the poker AT 49 : 8.02 AT 49 : 8.02 AT 49 : 8.02 AT 49 : 8.02
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(m/s ), according to ISO 8662-1. AT 59 : 10.42 AT 59 : 10.42 AT 59 : 10.42 AT 59 : 10.42
Protection Splash-proof Splash-proof Splash-proof Splash-proof
Dimensions : L x w x h (mm) 337 x 205 x 200 337 x 205 x 200 350 x 205 x 200 350 x 205 x 200
(in) 13 1/4 x 8 x 7 4/5 13 1/4 x 8 x 7 4/5 13 4/5 x 8 x 7 4/5 13 4/5 x 8 x 7 4/5
Weight Kg - (lb) 5.90 - (13) 5.90 - (13) 6.60 - (14.50) 6.60 - (14.50)

FLEXIBLE SHAFT (SUPERFLEX)


TECHNICAL DATA 10 15 20 30 40
P/N 362246 P/N 362248 P/N 362250 P/N 362252 P/N 362254
Length m - (ft) 1 - (3 1/4) 1.50 - (5) 2 - (6 1/2) 3 - (10) 4 - (13)
Weight Kg - (lb) 2.40 - (5) 3 - (6 5/8) 3.80 - (8 3/8) 5.60 - (12 3/8) 7.30 - (16)

VIBRATOR TUBE
TECHNICAL DATA AT 29 AT 39 AT 49 AT 59
P/N 108529200 P/N 108539200 P/N 108549200 P/N 108559200
Tube diameter mm - (in) 29 - (1 1/8) 39 - (1 1/2) 49 - (2) 59 - (2 3/8)
7/8
Tube weight Kg - (lb) 1.30 - (2 ) 2.10 - (4 5/8) 2.70 - (6) 3.90 - (8 5/8)
Tube lenght mm - (in) 332 - (13) 315 - (12 3/8) 311 - (12 1/4) 306 - (12)
Amplitude peak mm - (in) 0.80 - (0.03) 1.00 - (0.04) 1.20 - (0.05) 1.20 - (0.05)
Speed (rpm) 12 000 12 000 12 000 12 000

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OPERATION

CAUTION

DRIVE UNIT :
Double Insulated and splash-proof
Not able to be submersed or lain in water

DO NOT !
Run the drive unit in a vertical position (it should be horizontal)
Run the vibrator for long periods of time when not submersed in concrete
Bang the vibrator head on the ground
Allow the vibrator head to be in contact with bottom of the mold or the reinforcing bar for long periods of
time
Use the poker to move the concrete sideways
Clean the equipment with high pressure water jet.

CONNECTING THE UNIT

Before connecting, check that the recommended combination of drive motor, flexible shaft and vibrator tube have
been selected.

VIBRATOR (AT) FLEXIBLE SHAFT (SUPERFLEX)


10 15 20 30 40
AT 29 O O O O O
AT 39 O O O O O
AT 49 O O O O X
AT 59 O O O O X
O = Only AH15S to be used for driving.
X = Only AH25S to be used for driving.

Connect the flexible shaft on the drive unit : press the spring index of the SUPERFLEX to introduce it in the hole of the
nipple of the drive unit , then screw the vibrator tube securely to the flexible shaft (left-hand thread), taking care to
ensure that the square ends of the flexible shaft engage with the square screw cap on the motor and on the vibrator tube.
Check that the voltage of the main corresponds to the voltage of the electric drive unit.
Plug the drive unit and switch on.

VIBRATION

Pour the concrete evenly into the form in 30-50 cm thick layers.

DO NOT USE THE POKER VIBRATOR TO MOVE THE CONCRETE SIDEWAYS.

30-50cm

30-50cm

Vibrate systematically . Insert the poker vibrator 30-50 cm vertically into the concrete at centres which are 8-10 times the
diameter of the tube.
Push the poker vibrator about 15 cm into the earlier layer of concrete to obtain the best possible bonding between the
two layers.

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The concrete has been thoroughly vibrated when the surface around the poker vibrator becomes glossy and no large air
bubbles breaks surface. This normally takes 10-20 seconds. Withdraw the vibrator slowly so that the concrete
has time to flow back into the cavity left by the vibrator.
MAINTENANCE

DRIVE UNIT

At regular intervals check that air gaps for cooling the drive motor are clear.
Inspect brushes on a monthly basis or every 100 hours to build up records of expected change out time. Normal duty
would see them last for 250 hours but premature wear can occur because of dusty working conditions or intensive use.
To replace the brushes, remove the screws (10) and slide the unit outside the frame. Then remove the screws (2) holding
the two plastic parts of the motor housing (17), (18) and draw the parts until the brushes (20) can be reached. Also
replace the plastic protection or the rubber membrane (31) if it is damaged.

FLEXIBLE SHAFT

Disconnect the flexible shaft from the drive unit (spring index) and from the poker (left-hand thread).
Pull out the inner shaft and lubricate it with KLUBER GBU Y131 grease or equivalent every 75 h of operation. About 15
gr of grease is required per meter of the shaft.
Important : Do not overgrease the inner shafts. The effect of overgreasing is to overload the electric drive unit and to
release the breaker of the units which are equipped with. For these units it is recommended to run the vibrator in air
about 2 minutes before immersion in concrete in order to distribute the grease in the flexible shaft without stops of the
motor.

VIBRATOR TUBE

The bearings and seals will ultimately fail dependent on the intensity of the work site use, ambient temperature and
vibration feed back caused from the head coming in contact with the mold or reinforcing bar. Replacement bearing kits
are available from SVEDALA and should be installed at failure time.

AT 29 , 39 , 49 :
The bearings are greased with SKF HT 22 and do not normally require regreasing.

AT 59 :
The bearings are oil lubricated with SHELL TELLUS T 46 . Volume : 30 cm3. Replace the oil only when dismantling.

WIRING DIAGRAM

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DISASSEMBLY

ELECTRIC MOTOR

Dismantling
Remove the flexible shaft, from the motor.
Remove the screws (10) and slide the unit outside the frame, then remove the screws (2) and draw the two parts of the
motor housing (17), (18).

Replacing the brushes


Remove the screws (40) retaining the brushes and replace them at the same time.
The brushes automatically switch off the motor when it is time to change.

Switch / breaker
Disconnect the wires from the switch or the breaker (24).
Remove the rear cover (50).
Slide the flexible sheating (33) on the cable (32) or (54).
Remove the switch or the breaker (24).
Remove the clamp (36).

Rotor
To dismantle the rotor from the front flange (12) unscrew the square screw cap from the rotor (right-hand thread). Then
use a drift to drive the rotor from the bearing and bearing shield. Remove the snap ring (1) and press out the bearing (5).
Use a bearing extractor to press out the bearing (39) on the commutator side.
The commutator of the rotor may be turned down in a lathe when it is worn. This operation should be carried out in an
electric workshop. The diameter of a new commutator is 36 mm. The minimum diameter is 35,5 mm.

Stator
To dismantle the stator, remove the wires from the switch/breaker and brushes. Remove the screws securing the stator
and then draw the stator out of the motor housing.

FLEXIBLE SHAFT

The inner shaft may be drawn out the hose after the flexible shaft has been disconnected from the vibrator tube and the
drive unit. Remove the spring index in pushing the index inside the hose.

VIBRATOR TUBE

Remove the flexible shaft, from the vibrator tube (left-hand thread).

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Dismantling
First dismantle the end cap (right-hand thread) and tube connector (left-hand thread).
Unscrew the square screw cap on the drive side in locking the eccentric by inserting a screwdriver into the groove at the
end cap end.
Select suitable drifts from those listed in the table hereafter and drive the eccentric, together with two bearings, out of the
vibrator tube from the end cap end.
Then press the two bearings out of the vibrator tube.

SPECIAL WORKSHOP TOOLS AT29 AT39 AT49 AT59


Dismantling : bearings 701800 701800 701801 701801
seals 701800 701800 701800 701800
Assembling : bearings 701802 701804 701805 701806
seals 701803 701803 701803 701803
Handles for drifts : short 701808 701808 701808 701808
long 701807 701807 701807 701807
The tools numbers are stamped on the tools.

ASSEMBLING

ELECTRIC MOTOR

Stator/Rotor
Proceed in the reverse order.

Switch /breaker
Connect wires and supply cable according to the wiring diagram.
Ensure that the marks on the rubber protection (0-1) are correctly positioned in relation to those of the switch. Do not fit
damaged electric components (cable , switch , plug).

FLEXIBLE SHAFT
Lubricate the inner shaft as mentioned in the MAINTENANCE section.

VIBRATOR TUBE
Check the bearings, seal and square screw cap. These parts should be replaced at the same time.
Lubricate the bearings as mentioned in the MAINTENANCE section.
Press two bearings into the vibrator tube and then fit the eccentric and the two remaining bearings.
Then fit the seal and the square screw cap. Check that the eccentris rotates easily. It may be necessary to tap the end of
the eccentric gently in the axial direction to seat the bearings.
Then fit the end cap and the tube connector.