NSGV EVE-ER I, O, & M MANUAL

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2 TABLE OF CONTENTS Rail Layout.. Page 1 Support Placement...Page 1 Rail Assembly.Page 1 Rail Duct Connections.. Page 2 Rubber Lip Installation.. Page 3 Pneumatic End Stop. Page 4 End Stop. Page 4 End Cap.. Page 5 Balancer Installation. Page 5 Flexible Drop.... Page 5 Pressure Sensor & Transmitter Mounting..Page 6 Wireless Transmitter Instructions Page 7 & 8 Sensor Adjustment Page 8 Wireless Receiver..Page 9, 10, & 11 Wireless Control Panel. Page 12 Rail & Air Line Support. Page 13 Balancer Adjustment. Page 13 Trip Plate Installation... Page 14 Shop Air Attachment. Page 14 Start-Up... Page 14 Operation Page 15 Maintenance... Page 15 Trouble-Shooting Page 15

3 EXHAUSTING RAIL LAYOUT The Exhausting Rail is installed with the rail running parallel to the exhaust side of the apparatus. The support braces are positioned at a maximum of 24 apart and a minimum of 18 from the apparatus. The front of the rail should be a minimum of 36 from the front bay door and extend a minimum of 36 BEYOND where the exhaust pipe of the vehicle is located at the end of the run. The rail should be installed at a height that insures the flexible tube drop will reach the vehicle tailpipe. If the system is used for a drive-thru application, the back of the rail should be 24 from the rear bay door. The rail should be installed to place the top of the rail at 11 ft. (maximum height 12 ft.). The Exhausting Rail connects to the blower duct through the rear end cap on rails 30-0 in length or LESS. For systems over 30-0 in length, the connection will be made on the top of the rail with two or more transitions installed at equal distance from the center. All connections must be provided with a blast gate in order to balance the airflow to each rail installed. SUPPORT PLACEMENT The supports are used to attach the system to the building. Normally, Unistrut is sufficient for the rail support. The installation of the Exhausting Rail will require one support every 10-0 to To attach the rail to the support structure, simply slide a 1/2 bolt head into the top slot of the rail with the threaded portion pointing up and through the support structure. Tighten securely with associated fasteners. (See diagram Page 2) Once a determination has been made to where the ideal spot for the tube to hang down is achieved, the measurements can be marked on the bay floor using a chalk line and the transferred to the ceiling supports with a plumb bob. NOTE: The front and back supports should be mounted just outside the door track. Make sure that the flexible tube will not hit the door track if the adapter is attached to the vehicle at the door. EXHAUSTING RAIL ASSEMBLY The Exhausting Rail is used to create a system that is unlimited in length. Each aluminum rail section is 6 in diameter and 10-0 in length. The sections are joined together using connecting rods as described below. The rail connecting rods are used to join the rail sections together. The rods are inserted into the slots molded into the rail to half their length, then secured using the provided 5/16 set screws through the pre-tapped holes in the ends of the rail. (See diagram) NOTE: To make the alignment of the connecting rods easier, leave the top connecting rod protruding a 1/2 further out than the bottom two allowing the top rod to slide into and support the next rail while connecting the bottom two rods. 1

4 RAIL DUCT CONNECTIONS The diagram below shows a typical rail system with duct connections. The blast gates are used to balance the air movement in the system and can be adjusted to keep the rubber lips from sealing shut. The rail duct taps shall be evenly spaced to allow for equal air movement throughout the system. NOTE: MAKE SURE THE DUCT TAPS ARE NOT PLACED ON RAIL SPLICES. The duct taps may be placed on the top or the side of the rail. Make sure if the taps are mounted to the side of the rail that the crab will pass without interference. Once the proper positions for the rail taps have been determined, you will cut a hole in the rail the same size as the inner dimensions of the duct tap. After the section has been cut out, screw the duct tap to the rail using sheet-metal screws. National would suggest using a sealant under the edges of the duct tap before placing it in position. After the tap has been screwed to the rail, apply a sealant around the edges of the tap to insure an airtight seal. 2

5 RUBBER SEALING LIP INSTALLATION The rubber sealing lip inserts are used along the bottom of the suction rail to seal around a transition in the crab roller assembly and will be attached AFTER all rail sections are securely installed. The attachment of the rubber lip inserts will require the following items: - 1/4 gallon bucket of water - liquid dish detergent - clothe rags/sponge - 3 lb. hammer - 1 x 2 x 12 wooden block Installing the crab unit on the rail will help in the attachment of the rubber lips by holding the loose end as you move down the rail. On rails longer than 50-0 in length, there will be a splice in the lips. This is done by making sure that both ends are cut square. Apply a rubber adhesive to both ends and hold in place until dry. NOTE: Make sure the lip splice does not fall on a rail splice. To attach the rubber lips to the rail, unroll a section on the floor under the rail with the grooved side facing up and pull one end through the crab unit previously installed on the rail. Be sure to have approximately 4 to 5 of lip pulled through the crab unit to provide enough slack to make the lips easier to handle. Mix approximately 8oz. of liquid dish detergent in a 1/4 gallon of water. Use a rag to soap up both the rail channel and the portion of the lip to be inserted. Using your thumb, press in approximately 6 of the lip, leaving about 3 of over hang beyond the end of the rail. Then use the hammer and the 1 x 2 x 12 wooden block to tap in the remaining lip. NOTE: Make sure the grooved sides of the lips are facing in towards the middle of the rail. After both sides of the rail are inserted, allow a couple of days for shrinkage, then cut off the remaining rubber that is still extended past the end of the rail using a utility knife. NOTE: If the rubber lips start to move after a period of time, a sheet metal screw may be inserted into the rail and lips every 3 to 4. 3

6 PNEUMATIC END STOP INSTALLATION The pneumatic end stop is used to stop the crab units at a desired point for the nozzle to disconnect from the apparatus. The end stop slides onto and secures to the rail roller tracks with four 3/8 set screws. The pneumatic plunger will face toward the crab units. The plunger will make contact with the bumper on the crab unit to absorb the impact as the vehicle exits the bay. NOTE: At the end of the plunger is an adjustment valve. The valve must be adjusted to its maximum strength. To adjust, loosen the jam nut and turn the adjustment screw in until finger tight, and re-tighten the jam nut. END STOP INSTALLATION The rear end stop is used to stop the crab units at the rear of the rail. This end stop will be mounted in front of the airline/cable support bracket. The end stop will attach to the rail with supplied T-bolts that slide into the channel in the rails topside. The bumpers of the end stop will face the crab units. NOTE: The rear end stop is not designed for impact. If vehicles exit at both the front and rear of the rail a pneumatic stop will need to be installed. 4

7 END CAP INSTALLATION The supplied end caps shall be notched around the webbing of the rail and fastened in place using sheet metal screws. BALANCER INSTALLATION The balancer will attach to the crab unit with a provided D clamp. Make sure the balancer pulls the tubing completely back into the stored position when not attached to a vehicle. This can be determined by looking at the stop on the balancer and making sure it is up tight aginst the balancer. FLEXIBLE TUBE DROP INSTALLATION Attach the balancer end to the eyebolt in the lifting elbow. After the tube has been secured to the balancer slide the short non-attached end of flexible tube to the inlet on the crab plenum. Clamp the tube to the inlet using the provided breeze clamp and slide the rubber sleeve over the clamp. Once the tube has been securely mounted to the balancer, attach the double coiled hose to the pneumatic box attached to the crab. The Clear line will screw into the fitting closest to the edge of the pneumatic box. The Yellow line will attach to the remaining fitting. NOTE: There must be tension on the balancer when the flexible tube assembly is attached to the vehicle. If tube assembly length is too long, length must be cut from the portion of tube that goes to pneumatic adapter. Make sure the airline inside the tube assembly is not excessively long to where it bunches up inside the tube. If this happens it can reduce airflow in the system and cause damage to the airline itself. 5

8 PRESSURE SENSOR and TRANSMITTER MOUNTING 6

9 WIRELESS TRANSMITTER I, O & M MANUAL 7

10 WIRELESS TRANSMITTER cont. SENSOR ADJUSTMENT Adjust the sensor using the adjustment screw accessed through a hole in the sensors contact cover. Turning the screw clockwise will increase sensitivity and counter-clockwise will decrease sensitivity. To set the sensor at the level needed, connect the nozzle to the tailpipe of the apparatus and start the engine. If the system does not start, leave the engine running and turn the screw clockwise approximately 1/8 th of a turn. Repeat until the system starts. Shut off the engine and allow the system to time out. Then restart the engine. If the system does not start, repeat this process again. WARNING: If it becomes necessary to replace a sensor, turn off the power to the control panel. Personal injury may result due to unnecessary system start. Also, if the leads make contact when removed from the sensor, a signal will be sent to the receiver to start the blower. 8

11 WIRELESS RECEIVER (LOCATED INSIDE CONTROL PANEL) 9

12 WIRELESS RECEIVER cont. 10

13 WIRELESS RECEIVER cont. 11

14 WIRELESS CONTROL PANEL I, O & M MANUAL NOTE: Since each control panel is designed job specific, all wiring diagrams will be located inside the control panel. The wireless control panel is used as a means to start the system. When the pressure sensor actuates the transmitter a signal is sent to the R/F receiver in the control panel to start the blower. An adjustable timer incorporated into the control panel allows the blower to run for 1 to 10 minutes before timing out. The average setting used by most facilities is 3 minutes. The panel is provided with a switch to bypass the timer to run the blower in manual mode. When switched to the manual position the system will operate continuously. When the switch is returned to the auto position it will turn off the blower. A timer-reset button is provided to allow the system to be turned off manually. This convenience button is used to eliminate the need to adjust the timer or shut off the power to reset the timer when adjusting the sensors. The control panel should be located with consideration to the electrical panel, the blower location, and accessibility. The ability to gain easy access to the manual start switch is needed so that personnel can turn the system if needed. WARNING: If it becomes necessary to replace a sensor, turn off the power to the control panel. Damage to the panel may result if the sensor wires are allowed to touch ground on systems with direct wired sensors. 12

15 RAIL AIR LINE AND SUPPORT CABLE ATTACHMENT: The cable support brackets shall mount to channel in the top of rail. The brackets should be situated on the rail so that the cut out portion of the bracket is facing the crab. The front bracket will be the one with no air fittings. The back bracket will be the one with the air fittings. The back bracket will be mounted behind the rear end stop just in front of the end cap. The front bracket will be mounted in the channel above the Pneumatic End Stop. Once the brackets have been installed and securely tightened, cut approximately a 2-0 piece of cable. You will loop this cable through the small hole in the back bracket and cable-clamp in place. Attach the turnbuckle to the other end of the cable using a supplied turnbuckle. Next, using a different cable, attach one end of the cable to the front bracket by looping through the small hole and cable-clamping in place. Then you will thread the cable through the supplied coiled air line (going through the longer coil first if there is a splice). After this, attach the remaining end of the cable to the other side of the turnbuckle. AIR LINE ATTACHMENT: Once your cable has been secured, you will attach the coiled air line to the crab assembly and the back cable bracket using the supplied air fittings. If the air line drops in the middle, tighten the turnbuckle until it is tight. Note: If it is not possible to get the cable tight enough, another turnbuckle may be used at the front cable bracket. Attach the other turnbuckle as done at the back bracket. Note: On dual drop system there will be brackets, cable and air line on each side of the rail. When mounting the brackets, you will have one side s brackets mounted upside down compared to the other side.) BALANCER ADJUSTMENT - To increase the weight capacity, rotate F counter-clockwise using a wrench. - To decrease the weight capacity, press spring 8 in a clockwise direction while rotating F counter-clockwise using a wrench. TO INCREASE LIFTING CAPACITY TO DECREASE LIFTING CAPACITY 13

16 TRIP PLATE INSTALLATION The trip plate should be mounted to the channel in the top of the rail 4-0 from the door. NOTE: If it is a dual drop system, the second trip plate shall be mounted 2-0 back and on the opposite side from the front trip plate. The front trip plate will for the vehicle exiting the building first. The trip plate has slots allowing for up/down adjustment as well as forward/back adjustment. The forward/back should be adjusted so that the rocker arm on the crab hits the middle of the trip plate. For up/down adjustment, the rocker arm should actuate as the trip plate goes toward the door but not coming back. SHOP AIR ATTACHMENT The shop air should be attached to the fitting supplied at the back cable mounting bracket. After this has been done, insure that each regulator on each crab is set to 14 PSI. Failure to do this may cause the nozzle to rupture. START-UP Before a tube assembly is attached to a vehicle, several dry runs should be performed. This can be accomplished by pushing in on the manual Inflate/Deflate valve. This should inflate the pneumatic nozzle. Pull out on the valve to insure the nozzle deflates. Once we have determined this works, re-inflate the nozzle by pushing in on the valve and walk the crab assembly past the trip plate. This should deflate the nozzle. If the nozzle does not deflate, check to insure that the rocker arm pushes down far enough to actuate the valve. If this works and the nozzle still doesn t deflate, check all air line fittings and insure there are no leaks or fittings not attached. Once you have the system working, inflate the nozzle and walk the crab past the trip plate 4 or 5 times to insure it works every time. After this has been done, attach the nozzle to a vehicle tailpipe and start the vehicle. Make sure the blower starts when the engine of the vehicle starts. If it doesn t, check to make sure the pressure sensor, wireless transmitter, and receiver are set correctly (Pages 8, 7, & 9 respectively). If the blower still doesn t start, check the wiring of the control panel and blower. Once the blower starts up properly, it is time to drive the vehicle out of the building with the nozzle attached. The first time you want to go very slow to insure that the nozzle deflates and disengages properly. Insure that the balancer pulls the nozzle off of the floor once it has come off of the vehicle. If the nozzle does not come off of the vehicle properly make sure the balancer is set to the correct tension (Page 12). NOTE: DO NOT PUT TOO MUCH TENSION ON THE BALANCER AS THIS CAN CAUSE FLY BACK OF THE NOZZLE POTENTIALLY CAUSING PERSONAL INJURY OR DAMAGE TO EQUIPMENT. Once the vehicle has exited the building and the nozzle has disengaged, back the vehicle back to the edge of the door and re-attach the nozzle by slipping it over the vehicle tailpipe and pushing in on the valve. Slowly back the vehicle past the trip plate to make sure the nozzle stays inflated. If the nozzle deflates when passing the trip plate, check the height adjustment on the trip plate. If the nozzles deflates and disengages properly and stays inflated when passing the trip plate, this should be done 4 to 5 more times, increasing speed a little with each run. NOTE: THE MAXIMUM SPEED ANY VEHICLE SHOULD EXIT THE BUILDING IS 5 MPH. FAILURE TO DO SO MAY CAUSE INJURY TO PERSONEL OR EQUIPMENT. This concludes your Start-Up. 14

17 OPERATION 1. Hold the pneumatic adapter on the vehicle tailpipe and push in on the palm valve located on the side of the lower rigid tube. Hold the nozzle on tailpipe until the nozzle seals on the tailpipe. 2. Start the vehicle and the blower will automatically turn on. 3. Drive the vehicle out of the building. While doing this the crab assembly will travel with the vehicle until the rocker arm hits the trip plate at the end of the rail. This will deflate the nozzle and allow the nozzle to release from the tailpipe. 4. Upon returning to the station, pull the tube assembly to the edge of the door and re-attach the nozzle to the vehicle tailpipe by repeating Step 1. This will turn the blower back on for a period of 5 minutes. 5. Back the vehicle into the standard position and shut off the vehicle. NOTE: In the event that the pneumatic adapter doesn t deflate and come off like it should, the safety disconnect will break loose. If this happens, simply slide the rubber sleeve back onto the bottom of the rigid lower tube and clamp in place and slide pneumatic line back into larger pneumatic line. Do not tighten clamp all the way down as this will not allow the safety disconnect to break away as designed. WARNING: DO NOT RUN PUMP CHECKS WHILE THE TUBE ASSEMBLY IS ATTACHED TO THE VEHICLE. THIS WILL VOID ANY WARRANTY AS THE SYSTEM IS NOT DESIGNED FOR THIS. MAINTENANCE 1. Approximately once a month check to insure all bolts, screws, clamps, and air fittings are properly tightened. This will depend on the amount of usage on the system. 2. Periodically check to insure there is proper airflow through the tube drop. If the airflow is different or lower than needed, check the following: 3. Periodically check the flexible tube for any tearing or holes. TROUBLE SHOOTING - Insufficient Airflow: A. Blockages in flexible tube. B. Blast Gates are open sufficiently. C. Obstructions in the blower intake or discharge. D. The belts on the blower are properly tightened. - Pneumatic Adapter does not inflate: A. Make sure air compressor is on. B. Check regulator to insure it is on. (NO MORE THAN 14 PSI) C. Check air fittings for looseness or kinks. - Safety Disconnect consistently comes of before pneumatic adapter releases: A. Insure that clamp is not too tight. - Pneumatic Adapter does not deflate: A. Check to insure rocker arm on top of crab assembly is being engaged by trip plate. 15

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