INSTRUCTION MANUAL MAGNA RAIL

Transcription

1 R ENGLISH NR INSTRUCTION MANUAL MAGNA RAIL List of contents Declaration of conformity, CE Delivery check Mounting instruction (rail, trolley units) Mounting instruction (exhaust pipe, anchor plate, nozzle) Wiring diagram Fan selection Installation checklist Automatic start/stop device for fan User instruction Maintenance instruction Trouble-shooting schedule Spare parts Page

2 R This product is designed to meet the requirements of the relevant EC directives. To maintain this status all installation, repair and maintenance work must be carried out by qualified personnel using only original spare parts. Contact your nearest authorised dealer or AB Ph. Nederman & Co. for advice on technical service or if you require spare parts. Declaration of conformity We, AB Ph. Nederman & Co., declare under our sole responsibility that the Nederman Magna Rail products: - Trolley with upper vertical hose - Nozzle with lower vertical hose to which this declaration relates, are in conformity with the following standards or other normative documents: EN 292-1:1991, EN 292-2:1991, EN , EN , EN class B, EN , EN , EN , EN , EN , EN , EN following the provisions of Directive 89/392/EEC, 89/336/EEC, 73/23/EEC, 93/68/EEC. AB Ph. Nederman & Co. Sydhamnsgatan 2 S Helsingborg Sweden Hans Engström, Marketing and Development Manager 2

3 Magna Rail extraction system, designed for use with emergency vehicles, is flexible and easy to use. The system is also suitable for lorries, buses, and other vehicles with exhaust pipes located beneath, at the back or the side of the vehicle. The system is particularly well suited for stations where two vehicles have their own individual parking spaces after each other. However, the system is also well suited for use with only one vehicle. The station can have drive in doors at one side of the building and drive out doors at the opposite side. The system is also possible to use in stations with doors only at one side of the building, where it is necessary to reverse the vehicles into their parking spaces. To guarantee a correct function and a minimal service, it is important to read and understand the information in this instruction manual. The manual contains important warning directions which have to be read and followed. DELIVERY CHECK 1 Magna Rail is delivered in the following units. A. Horizontal exhaust rail B. Trolley incl. upper vertical hose. C. Nozzle incl. lower vertical hose. D. Adaptor for fan duct (accessory, should not be used if the fan duct is mounted to the rail s end. Check that the following components are delivered A. Horizontal exhaust rail 1. Upper guide tracks (check that the number of tracks, end to end, make the total rail length required). 2. Side guide tracks (check that the number of tracks, end to end, make the total rail length required). 3. Rubber seals, 2 pcs. (check that the length corresponds with the total rail length required). 4. Connection box 5. Lock bars 6. Assembly bars (one pair) 7. Mounting brackets (check that the number of brackets correspond with the total rail length required). 8. Magnet holders (one pair) 9. Steel bands, 2 pcs. 10. Stop profile (one per trolley) 11. Rubber stops (4 pcs.) 12. Caps (2 pcs.) B. Trolley incl. upper vertical hose 13. Trolley (delivered complete assembled with upper vertical hose, electromagnetic unit, current collectors, balancer, and disconnection box). 14. Anchor plate * 15. This instruction manual B C. Nozzle incl. lower vertical hose 16. Nozzle with hose fitted. 17. Hose clip / rubber ring 18. Mounting instruction * As an alternative an anchor plate, specially designed for roll front doors on the emergency vehicles, can be ordered as an option. Please contact your Nederman representative for more information. 12 D C

4 ASSEMBLY INSTRUCTION (RAIL, TROLLEY UNITS) Before the exhaust track can be installed, a suitable height must be determined in relation to the vehicle's parking space in the garage. The distance from the floor to the bottom edge of the track should normally be 3-5 m. The track should be installed at least 0.3 m from the side of the garage opening (see figure). If Magna Rail is to be used between two vehicles, the distance between the vehicles must be at least 0,6 m. The distance from the rail's leading edge to the station door should as small as possible, as long the door can open freely without interference to the rail. Because of the module construction and the possibility to choose a 3 m or a 4 m vertical hose, the MagnaTrack can be adjusted to existing station measurements. Cutting the horizontal or vertical hose is therefore not recommended. In exceptional cases, for example at damages, cutting the hoses can be accepted. To avoid incorrect function the vertical hose must only be shortened with help of a Nederman mounting kit. Part no Mounting kit for cutting the upper part of upper vertical hose Mounting kit for cutting the lower part of upper vertical hose. 0,3-0,5 m min. 0,3 m 3-5 m 1 Ceiling mounting Secure the mounting brackets directly to the ceiling or support beams or similar. (Bracing the rail, see point 2 next page) Wall mounting Secure the mounting brackets to wall support beams or similar Brace the rail sideways at the first and the last beam. (Also see point 2, next page.) mm max. 5,0 m WARNING! Risk of personal injury! When mounting MagnaTrack, check that the system will not snag protruding parts on the vehicle when driving in or out mm The mounting brackets should be fitted with a distance of maximum 5 metres apart. If the ceiling height is low, it could be enough to use only the lower fitting hooks. Ensure that suitable fixing bolts are used and that they are secure. The bolts must each stand a torque force of minimum xxxx N. Also see point 6. 4

5 2 Bracing the rail when wall mounted Bracing the rail when ceiling mounted Forward direction of vehicle Brace the rail at the first and last wall support beams. Forward direction of vehicle Brace the rail with a reverse angled bracing bar at the first mounting brackets (see picture) and a forward angled bracing bar at the last mounting brackets. 3 Assemble the rail s upper and side guidetrack on the floor (according to alternative 1 or 2). Up to 20 m of the rail can possibly be assembled on the floor. IMPORTANT! Check that the floor is level. If the floor is not level the rail can be assemled directly in the ceiling. In that case, begin with fitting a 5 m upper guidetrack to two pair of mounting brackets positioned with a distance of 4 m from each other. NB! Ensure that the upper guide tracks are matched, which means that the rippled markings are both in line on one side of the rail. If necessary remove burrs from the guide track joints. ALT. 1 7,5 m ALT m 5

6 4 Fit the lock bars along the side guide track at a distance of 1 m. Always fit a lock bar over the joints according to the illustration. Wheel track for the trolley guide wheels Ø 5,5 2 ~ 15 mm Drill a hole Ø 5,5 mm through the lock bars and fix them with the screws. IMPORTANT! The drilled holes must not damage the wheel track for the trolley guide wheels. For that reason hold the drilling machine in a way that the marked angle in the illustration will be not more than The side guidetracks must fit in right position. 5 Fit the connection pipe in the desired position As an alternative the fan duct can be mounted to the rail's end. In that case it is best to assemble the whole rail before the connection is made. 6

7 Fit the assembled rail into the mounting brackets. The distance from the first bracket to the tracks end must be max mm. If necessary, adjust the track so that it will be level in two directions. Always fix the locking screw immediately when the bracket has been fitted to the rail profile. 6 max mm ~ 1000 mm 7 Install the next upper guide track with help from the assembly bars which should be located into the tracks outer wheel conveyor as guide. Install the guide tracks and lock them with the lock bars. Drill through and secure with the screws (see item 3). Relocate the assembly bars to the next joint and repeat the above procedure. NB! The assembly bars are only a help when assembling the tracks. They shall be removed when the assemble work is finished

8 8 Install the rubber seals in following manner: A. Hang the seal with strings to facilitate the mounting. B. Spray or paint soap solution, glycerin or parafin oil on that part of the seal which shall be pressed into the profile mark. C. Fit the lower edge of the seal to the profile mark on approx. 1 m. NB! Leave 100 mm of the seal outside the rail end. D. Press the upper edge of the seal at point b with a screw driver. E. Press and guide the seal into the profile mark from a to b with a screw driver. F. Continue in the same manner the seal installing in intervals of 1 m. G. Connect the seal with a screw, B8x19, 50 mm from the rails end. H. Cut away those parts of the seal that hangs outside the rail ends. J. To ensure correct fitting of end locks, the seal ends have to be adjusted. Cut away 16x25 mm according to picture. 100 mm 50 mm ~ 1 m H a C b D A Ø 3,5 G B8x19 25 mm B SOAP J 16 mm E 8

9 A B 100 mm ~ 1 m C D a b E F 9 Install the steel bands for current collecting in following manner: A. Open the packing, loosen the four clamp rings and cut up the packing according to diagram. B. Draw out the cable shoe end of steel band from the packing. Avoid sharp bends. Close the packing. C. Hang the band with strings to facilitate the mounting. D. Fit the lower edge of the steel band to the rubber seal profile mark on approx. 1 m. IMPORTANT! The band should be mounted 100 mm from end of the rail. E. Press the upper edge of the band at point b with a screw driver. F. Press the band into the mark at b with one hand and at the same time guide the band into the rubber seal mark from a top b with a screw driver. G. Continue in the same manner the steel band installing in intervals of 1 m. 9

10 10 The extraction units are different from each other and marked 1 and 2. Install extraction unit 1 closest to the garage door with its balancer in the forward direction of vehicle. Install extraction unit 2 behind extraction unit 1 with its balancer facing from the garage door. IMPORTANT! Bend the current collectors carefully outwards when the units are installed. Make sure the current collectors fit properly against the collector rail. MAGNA RAIL 1 2 a max. 1 mm max. 1 mm x x x IMPORTANT! To ensure unproblematic running the exhaust trolleys must be centred in the exhaust rail. Adjust the guide wheels with the screws (a). Then check that the x-measurements are equal. x 11 Mount stop profiles and magnet holders IMPORTANT! on the front part of the exhaust rail according to the figures. To make sure the extraction units don t crash into each other after a turn-out, it is important that the distance between the stop profiles is minimum 800 mm. Magnet holder 700 mm min. 800 mm Stop profile The rail seen from above Forward direction of vehicle Magnet holder 700 mm Stop profile 10

11 Ø 3,5 MAGNA RAIL 12 Install the transformer on the top of and in the back side of the rail. Connect the collector rails to the transformer with cable and cable shoe (see wiring diagram, page 14). 150 Ø 7,0 Use the transformer fitting plate as a template to drill the holes. 13 Fit rubber stops and plastic end caps in the rail ends. Eventually the fan duct can be mounted to one end (see point 5). 30 mm Ø 3,5 B8x13 50 mm 50 mm B8x19 Ø 7,0 11

12 MUNTING INSTRUCTIONS (EXHAUST PIPE, ANCHOR PLATE, NOZZLE ) The exhaust pipe (for standard- and HB-nozzle) For the best results, side mounted exhaust pipes should be positioned according to the figure and point at right angles to the coachwork or a little backwards, yet not more than 45. The pipe should be straight and lie flush with or protrude slightly out from the side of the vehicle. It is possible that modifications may be required to the exhaust system of the vehicle to ensure the optimum position of the exhaust pipe. Anchor plate for standard nozzle The anchor plate should be fitted to the side of the vehicle according to the measurements given in the figure /- 200 mm min. 200 mm 250 +/- 150 mm Standard nozzle Fit the chain lock in the electromagnetic unit as shown in the figure. Fit the hose in the electromagnetic unit with the hose clip and cover with the rubber ring. Forward direction of vehicle min. 300 mm max Check that the nozzle, when not connected to the vehicle, is pointing forward in the driving direction. Adjusting screw. For adjusting the spring power in the nozzle after fitting the anchor plate. NB! In the opening of the standard nozzle there are two landing (friction) pads. The metal pad must be in front of the rubber pad when viewed in relation to the forward drive direction of the vehicle. Locate the nozzle on to the exhaust pipe and secure the electromagnetic unit on the anchor plate making sure the hose is tensioned correctly. The hose should form a 90 bend coming out from the exhaust pipe (see figure next page). Forward direction of vehicle The metal pad must be fitted on this side. 12

13 Anchor plate for nozzle model HB The anchor plate should be fitted to the side of the vehicle 600 mm from the exhaust pipe. If necessary this distance can be changed (+100 mm, -25 mm) by loosening the adjusting screw in the electromagnetic unit. Nozzle model HB Fit the nozzle leaf spring in the electromagnetic unit with the adjusting screw as shown in the figure. Fit the hose in the magnetic unit with the hose clip and cover with the rubber ring. min. 200 mm max. 20 X max. 20 min. 300 mm max. 50 mm Forward direction of vehicle X = 600 (+100 / -25) mm or 900 (+100 / -25) mm depending on nozzle hose length Adjusting screw. When the anchor plate has been fixed in its correct position, it is possible to adjust the nozzle by loosening the adjusting screw and moving the leaf spring some upwards or downwards. IMPORTANT! If the leaf spring is moved upwards it must not come in contact with the upper hose. If neccessary its upper end should be cut off. Check that the nozzle, when not connected to the vehicle, is pointing forward in the driving direction. Locate the nozzle on to the exhaust pipe and secure the elctromagnetic unit on the anchor plate making sure the hose is tensioned correctly (see figures to the right). Fitting the standard- or HB-nozzle Alternative fitting of HB-nozzle. When hose and nozzle are connected to the vehicle the hose should form a 90 bend coming out from the exhaust pipe. 13

14 WIRING DIAGRAM Connection to the mains should be carried out by a qualified electrician. PTC fuse, breaks at high power Transformer Secundary voltage: 26 V AC Power consumtion: 0,2 A Capacity: 8 VA Connection box 230 V Block, 3-4 connected at delivery PE N L PE N L Service breaker, not included in the package PE Power supply 230 V or 115 V AC, 1~ 24 V DC 115 V Disconnection box Block, 2-4 & 3-5 should be carried out by electrician PE N L 24 V DC Vertical hose with cable Ground cable Vertical hose with cable Ground cable Disconnection box Circuit breaker Electro magnet Circuit breaker Electro magnet VDR VDR 14

15 FAN SELECTION Pa 4000 NCF 120/25 Fans are not included in the basic package. For the best results, one fan per extraction unit is recommended. It is also possible to connect several units to a central fan ,5 kw 529 2,2 kw NCF 50/ NCF 30/15 NCF 30/25 NCF 80/15 NCF 80/25 If a central fan is used for connection to several MagnA Rail, a suitable fan from the Nederman NCF-program can be chosen. Please contact your Nederman representative for advice on fan selection. To get underpressure in the ducting system and avoid exhaust leakage, the fan should be positioned as near the outlet from the room as possible. NCF 50/15 A lockable safety switch is recommended for the electrical system including the fan. NCF 120/ N16 N24 N40 P d P d P d P d P d P d m /h Required fan capacity per system Only one extraction unit in use Rail length 10 m: 1300 Pa vid 1000 m 3 /h Rail length 15 m: 1400 Pa vid 1000 m 3 /h Rail length 20 m: 1500 Pa vid 1000 m 3 /h Rail length 25 m: 1600 Pa vid 1000 m 3 /h Rail length 30 m: 1700 Pa vid 1000 m 3 /h Please note that the pressure drop in the rail must not exceed 2700 Pa. Otherwise the exhaust trolley will not move freely. Duct type A Two extraction units in use at the same time Rail length 10 m: 1800 Pa vid 2000 m 3 /h Rail length 15 m: 2150 Pa vid 2000 m 3 /h Rail length 20 m: 2500 Pa vid 2000 m 3 /h Rail length 25 m: * 2000 Pa vid 2000 m 3 /h Rail length 30 m: * 2200 Pa vid 2000 m 3 /h * Valid for fan connected to the centre of the rail (duct type B). Other capacity values are valid for fan connected to the end of rail (duct type A). Duct type B = = 15

16 INSTALLATION CHECKLIST When the mechanical assembly, fan connection and electrical installation of MagnaTrack is complete, the system is ready for use after double- checking the following points. Check the disconnection procedure. The extraction hose should disconnect from the exhaust pipe immediately before the station door opening at normal speed, not more than 20 km/h. Adjust the disconnection position by moving the disconnection magnet on the front rail (see assembly instructions, point 11). Check that the hose lifts away correctly after disconnection and that it does not touch the station floor. When required, adjust the balancer lifting power according to the instructions in the maintenance instructions (page 18). Check that the hose does not catch any part of the vehicle or the station door. Check the air flow ( m 3 /h for 6" nozzle and m 3 /h for 5" nozzle at idling speed are normally recommended) in the nozzle opening with an air flow indicator. If required, check the fan impeller rotation direction and/or damper function. Check the electrical installation (connection box, disconnection boxes, breakers, electro magnet) according to the wiring diagram. Make sure the extraction unit no. 1 stops properly in its stop profile. If the disconnection does not work at all in the forward direction, move the contact in the disconnection box according to this figure. Check that the extraction units don t crash into each other after a turn-out. If so, check if the distance between the stop profiles is at least 800 mm. Check that the rail has been braced (see example page 5) so it is stable when it is in operation. Clean the rubber seals internally. Clean the trolley wheel tracks in the rail. AUTOMATIC START/STOP DEVICE FOR FAN As an alternative the fan can be automatically activated by a start/stop device which can be ordered as an option. Please contact your Nederman representative for more information. 16

17 USER INSTRUCTION Connection 1. Open the station door and start the exhaust extraction fan (as an alternative the fan can be connected to an automatic start/stop-system). 2. Drive or reverse the vehicle in so that the exhaust pipe is just outside the station door.,,,, MAGNA RAIL 3. Locate the nozzle of the flexible hose on the exhaust pipe. Fasten the electromagnetic unit onto the anchor plate located on the side of the vehicle. max. 1 m The illustration shows a station where the vehicles are reversed into there parking spaces. 4. Drive or reverse the vehicle into its parking space. The hose should always be connected to the exhaust pipe while the vehicle is parked in the station. Fitting the standard- or HB-nozzle Alternative fitting of HB-nozzle A manual disconnection from the anchor plate is possible with a switch on the electromagnet unit. Disconnection 1. Make sure the extraction hose is connected to the exhaust pipe and that it is firmly fastened to the anchor plate on the vehicle's side. 2. Start the fan and open the station door. Drive the vehicle straight out from the garage with a maximum speed of 20 km/h. The hose automatically disconnects when the vehicle is driven out. The flexible hose can withstand 150 C for continuous running and 180 for short periods. Use at higher temperatures will shorten the life of the product. Therefore, avoid tasks that require extended periods of continous running which will generate high exhaust temperatures. WARNING! Risk of personal injuries and/or product damages. The system must only be used in combination with the anchor plate which should be mounted on the vehicle. The system must not be used when working on the vehicle s fuel system, when recharging the batteries or whenever there is a risk for inflammable dust or explosive gases. The system must be disconnected and must not be exposed for water when washing the vehicle. The system is designed for use only in the direction of the length of the rail. The system must not be used for other purposes than extracting exhausts. Check that there is enough suction capacity in the exhaust hose before it is connected to the vehicle exhaust pipe. If needed, check the fan impeller rotation direction and/or damper function. Check that the nozzle is correctly fitted to the exhaust pipe after the vehicle has been moved. Check that the hose or nozzle will not snag on any protruding parts on the vehicle. 17

18 MAINTENANCE INSTRUCTIONS In order to ensure that the system continues to operate correctly, the following should be checked at periodic intervals depending on the amount of use. Defective and worn parts should be replaced immediately WARNING! Risk of personal injury! A dust filter mask should be used during service and repairs inside the system, specially when working on the nozzle and hose Check the following points once a month 1. The nozzle's internal contact surfaces. Clean when necessary. 2. The electro magnetic operation. Check the attachment with the connector and clean the magnet and anchor plate on the vehicle when necessary. 3. Disconnection position. The extraction hose should disconnect from the exhaust pipe immediately before the station door opening at normal speed, not more than 20 km/h. Adjust the disconnection position by moving the disconnection magnet on the front rail (see assembly instructions, point 11). 4. The operation of the balancer, make sure that the hose lifts up properly. If necessary, adjust the lifting power of the balancer according to the instruction below. 7 2 Check the following points once a year or when needed. 5. The mounting brackets. 6. The cable on the balance block. 7. The hoses. 8. The current collectors. 9. The wheels and the low-friction material on the extraction units. 10. The function of the stop profiles. 11. Clean and remove dirt and oil from the collector steel bands. 12. Clean and remove dirt and oil from the rubber strips. 13. Electrical installation (see the wiring diagram). 1 The balancer s spring power has a correct setting from the factory. However it is advisable to check regularly that the hose lifts up properly and does not drag on the floor. When required the spring power can be increased in the following manner. Increasing the spring power 1. Hold the adjustment wheel firmly with one hand. 2. Turn the balancer drum with the other hand a 1/4 turn (= 1 click) at a time. WARNING! Risk of personal injury! During repair work on the balancer, for example when changing cord - Neutralize the spring power in the balancer. 18

19 TROUBLE-SHOOTING SCHEDULE Possible faults Causes Actions The trolley sticks or disconnects too late. 1. Disconnection outside the station. 2. The electromagnetic unit does not disconnect from the anchor disc. 1. Move the disconnection magnet further from the rails end (see mounting instr. point 11). 2. Check the function of the disconnection box. The nozzle sticks or is damaged. 1. Disconnection outside the station. 2. The friction pads in the nozzle are missing, defective or fitted incorrectly. 3. The nozzle gets stuck in the exhaust pipe. 4. The nozzle is dragged on the floor. 5. The grille in the nozzle is missing or has been deformed. 6. The exhaust pipe is loose or has been deformed. 1. Move the disconnection magnet further from the rails end (see mounting instr. point 11). 2. Change the pads or fit them correctly according to the instruction page Correct the exhaust pipe if damaged or change the position of the exhaust pipe or the anchor plate according to instruction page Check the function of the balancer and, if necessary, adjust the lifting power according to instruction page Change the grille or correct the damage. 6. Fit the exhaust pipe or correct the damage. The nozzle releases too early. 1. The holding power in the standard nozzle is too weak. 2. Incorrect position of the anchor plate on the vehicle. 3. Incorrect position of the disconnection magnet on the rail. 4. The friction pads in the nozzle are missing, defected or fitted incorrectly. 5. The spring power in the HBnozzle is too high. 1. Increase the spring power according to instruction page Correct the position of the anchor plate according to the instruction page Correct the position of the disconnection magnet on the rail according to the instruction page 10 point Change the pads or fit them correctly according to the instruction page Check the position of the anchor plate and the exhaust pipe (see instr. page 13). The trolley sticks or runs badly in the rail. 1. The rail joints are irregular or too big. 2. The trolley is not centred in the exhaust rail. 3. The trolley wheels are worn or defected. 1. Check the rail joints sizes and grind them at the wheel tracks. 2. Centre the trolley according to instruction at page Change the wheels. 19

20 Possible faults Causes Actions The suction capacity in the nozzle is too low. 1. Obstruction in the nozzle, hose or duct. 2. Incorrect fan function. 3. Incorrect damper or duct function. 1. Remove the obstruction. 2. Check the start function of the fan and/ or the rotation direction of the impeller (according to the arrow on the fan motor). 3. Check that dampers, if any, are opened and that there is no leakage in ducts, hoses or joints. The electromagnetic unit comes loose or does not attach on the anchor plate. 1. Electrical faults. 2. Dirty magnet or anchor plate. 3. The spring power in the HBnozzle is too high. 4. The circuit breaker on the electromagnetic unit does not work. 1. Check and take measures according to wiring diagram page Clean. 3. Check the position of the anchor plate in relation to the exhaust pipe (see instr. page 13). 4. Change the electromagnetic unit. The electromagnetic unit does not detach. 1. Electrical faults. 2. Incorrect positioning of the disconnection magnet on the rail. 3. Incorrect positioning of the connection box on the trolley. 1. Check and take measures according to wiring diagram page 14 (should be carried out by a qualified electrician). 2. Correct the position of the disconnection magnet on the rail according to the instruction page 10 point Mount according to instruction which comes together with spare part connection box. The extraction units crash into each other after a turn-out. The distance between the stop profiles are too close. Increase the distance between the stop profiles to at least 800 mm. The rail swings along at disconnection. The rail has not been braced properly. Brace the rail according to instruction point 2 at page 5. 20

21 SPARE PARTS Ordering Instructions When ordering spare parts always indicate the following: A. Article No. and Control No. (see sign plate at the balancer) B. The spare part's name and number (see list to the right). C. Quantity of parts required Spare Parts List Description 1 Balancer, complete 4 Recoil package incl. spring hub 5 Cord with stop pipe 6 Adjustment wheel 9 Nozzle with hose and spring 10 Friction blocks, pair 11 Nozzle without spring 12 Hose for nozzle 13 Vertical hose 14 Electromagnetic unit 15 Anchor plate 20 Transformer (mounted on top of rail) 24 Current collector 25 Rubber seals with collector steel rail, pair 26 Guide wheel, set 27 Wheel, set 28 Lowfriction foil (pair) 34 Gas spring 35 Reducer mm 36 Magnet holder 37 Disconnection box 11 10