Nederman 920/1500 Manual

Installation and service manual
Exhaust Extraction
Trolley Return Unit 920/1500
144259(02)
Original installation and service manual
INSTALLATION AND SERVICE MANUAL EN

Trolley Return Unit 920/1500
2

Trolley Return Unit 920/1500
3
English......................................................................................................................................................4

Trolley Return Unit 920/1500
EN
4
English
Installation and service manual
Exhaust Extraction
Trolley Return Unit 920/1500
1 Declaration of conformity......................................................................................................... 5
2 Preface......................................................................................................................................................... 5
3 Notices......................................................................................................................................................... 5
4 Description.............................................................................................................................................. 6
4.1 Components..................................................................................................................................6
4.2 Technical information...............................................................................................................8
5 Installation................................................................................................................................................ 8
5.1 Assembly instructions Trolley Return Unit 920/1500.........................................8
5.2 Description of cable and end marking......................................................................17
5.3 Installation of cables and connection boxes........................................................17
5.4 Electrical continuous test (2 persons required).................................................20
5.4.1 Check cable W1 ...................................................................................................................20
5.4.2 Wiring tests ............................................................................................................................21
5.5 Installation checking .............................................................................................................24
6 Work procedure (Normal operation).........................................................................25
7 Malfunction (Drive unit motor moves the suction trolley)....................25
8 Spare parts...........................................................................................................................................26
9 Troubleshooting...............................................................................................................................27
Appendix A: Cable connections................................................28
Cable connections overview.....................................................................28
Simple cable connections overview.......................................................... 29
Appendix B: Circuit diagrams ...................................................30
Driving slot circuit diagram .......................................................................30
Circuit diagram 1 ......................................................................................31
Circuit diagram 2.......................................................................................32
Circuit diagram 3.......................................................................................33
Circuit diagram 4.......................................................................................34
Circuit diagram 5.......................................................................................35
Circuit diagram 6.......................................................................................36
Circuit diagram 7.......................................................................................37
Circuit diagram 8.......................................................................................38
Circuit diagram 9.......................................................................................39
Circuit diagram 10.....................................................................................40
Table of contents

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1 Declaration of conformity
We, AB Ph. Nederman & Co., declare under our sole responsibility that the Nederman
product:
Suction Trolley Return Unit 920/1500 with accessories to which this declaration relates,
are in conformity with the following:
Directives
2006/42/EC
Standards
EN ISO 12100-1-2
The Manager of Development and Engineering, Lena Åberg, is responsible for the
technical documentation.
AB Ph. Nederman & Co.
P.O. Box 602
SE-251 06 Helsingborg
Sweden
Lena Åberg
Manager, Development and Engineering
2 Preface
This manual is for the correct installation and maintenance of this product. Read it
carefully before using this product or carrying out maintenance. Replace the manual
immediately if lost.
This product has been designed to meet the requirements of relevant EC directives. To
maintain this status, all installation, repair and maintenance work for this product is to
be carried out by qualied personnel using only original spare parts. Contact the nearest
authorized distributor or Nederman for advice on technical service and obtaining spare
parts.
Nederman continuously improves its products’ design and efciency through
modications, and reserves the right to do so without introducing these improvements
to previously supplied products. Nederman also reserve the right to, without previous
notice, modify data and equipment as well as operating and maintenance instructions.
3 Notices
This document contains important information that is presented either as a warning,
caution or note. See the following examples:
WARNING! Type of injury.
Warnings indicate a potential hazard to the health and safety of personnel, and how that
hazard may be avoided.
Caution! Type of risk.
Cautions indicate a potential hazard to the product but not to personnel, and how that
hazard may be avoided.
NOTE! Notes contain other information that is important for personnel.

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4 Description
4.1 Components
See Figure 1 Component overview, and ‘Table 4-1: Component descriptions’ below.
Table 4-1: Component descriptions
Component Description Explanation/location
SLX Limit switch on suction
trolley Detects transport position (suction hose fully raised).
SLX 1 Disconnection arrow Disconnects the stop ball from the driving slot and connects limit
position SLX to the control system in connection position.
SLX 3 Bus bar Connects SLX to the control system in disconnection position.
SL2 Inductive sensor Detects when the suction trolley passes, activating speed reduction.
SL4 Limit switch Detects when the stop ball passes, disengaging the drive motor.
C_BOX_1 Connection box Vehicle exit end.
C_BOX_2 Connection box Vehicle entrance end.
C_BOX_3 Connection box Accessory location in the centre of the extraction rail, same as
C_BOX_2.
CR_BOX_1 2-button control box Emergency stop and Start button.
Figure 1 Component overview
Drive unit
Connection box 1
Idler pulley unit
End cover
Connection box 2
driving slot
Guide pulley
(on the middle of
the rail´s mounting
brackets)
Wire
Limit switch SL4
Limit switch
SLX
Bus bar SLX3
Disconnection arrowSLX1
Inductive sensor SL2
Control box
(start / stop)
Control box
(manual / auto)
Motor damper
Wire stop with spring
Suction rail
Balance
block
Figure 1 (Overview components)

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Component Description Explanation/location
CR_BOX_2 3-button control box Emergency stop, Start button and a rotary switch Manual/Automatic
return.
CR_BOX_3 2-button control box Emergency stop and Start button.
Damper Motor Damper motor Closes extraction channel, and counteracts cold downdraft.
Fan Contactor Start apparatus for fan Start apparatus for fan with motor protection.
Trolley Suction trolley Trolley with a balance block, which runs inside the extraction
channel.
Current Collector Current collector Carbon brushes mounted on driving slot, connecting SLX with
control system through SLX3.
Bus Bar Bus bar
J1 Jumper Jumper for supplying galvanically separated relay with 24 VAC.
X1 Terminal block designation Network connection in Drive Unit.
X2 Terminal block designation Connection for cable W1 in Drive Unit.
X3 Terminal block designation Terminal block in connection box 1.
X4 Terminal block designation Terminal block in connection box 2.
X5 Terminal block designation Connections on the driving slot.
X6 Terminal block designation Terminal block in connection box 3.
Drive Unit Drive unit Complete unit containing the drive motor, control board, transformer,
gearbox, drive wheels, and so on.
K1 Contact Contact for the disconnection of the motor when the emergency stop
is activated.
K2 Relay Relay for galvanic separation of Fan Starters.
F Fuse 10 A time lag (T) Fuse in control board, 10 A time lag (T), fusing the drive motor.
F1 Fuse 2 A time lag (T) Fuse in terminal block X1, (2 or 4 A time lag (T) depending on
transformer voltage setting according to Circuit diagram 1), power
supply fusing of 24 V transformer.
F2 Fuse 2 A time lag (T) Fuse in terminal block X2, 2 A time lag (T), 24 VAC, fusing of 24 VAC
supply to Fan Contact.
T1 Transformer Power transformer 115/100V, 200/230V, 24V.
PCB1 Control board Printed circuit board, control board in drive unit.
PCB2 I/O card Printed circuit board, adjusts inputs to PCB1.
M Drive motor 24 VDC motor with gearbox for propulsion of the retrieve wire.
Driving slot Driving slot Mechanical safety coupling for interconnection of stop ball and
suction trolley.
Ball Stop ball Ball-shaped stop device mounted on the retrieve wire. Locks into
driving slot and pulls the suction trolley back to connection position.
Retrieve wire Retrieve wire The wire runs between drive wheel and idler pulley. Fitted on this is
the stop ball that is connected together with the driving slot.
Connection pos. Connection position When the driving slot is inserted in the connection arrow SLX1.
Disconnection pos. Disconnection position The disconnection position when the driving slot’s current collector
is connected with the bus bars. The disconnection zone is
approximately. 2.5 m at the exit point.
Transport pos. Transport position The transport position when the exhaust hose is in its uppermost
position and aects the limit position SLX.

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4.2 Technical information
Table 4-2: Technical data
Trolley Return Unit 920/1500
Rail length Maximum 35 m
Suction unit (1 per rail) 920–1500
Return time for suction trolley < 1 minute.
Voltage, primary side 100/115/200/230/240 V AC
Phase, primary side 1-phase
Frequency, primary side 50/60 Hz
Voltage, secondary side 24 V AC
Protection class IP 21
5 Installation
5.1 Assembly instructions Trolley Return Unit 920/1500
First of all decide if the Trolley Return Unit is to be installed on the Left Hand side (LH)
or the Right Hand side (RH) of the 920-rail as seen from the vehicle’s travel direction,
see Figure 2.
Consideration must be taken to available space and which other system (with special
needs) shall be tted to the rail. For example a Magna Rail System shall be installed
on the same side as the vehicle is situated, and consequently the return system must be
Figure 2
Left Hand installation (LH)
Vehicle arrivalVehicle departure
Vehicle travel direction
a
Right Hand installation (RH)
Vehicle departureVehicle arrival
Vehicle travel direction
b
b
a

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installed on the other side. Allow for installation dimensions from the rail prole’s centre,
horizontally in each direction, of at least 400 mm.
NOTE! This installation instruction describes a LH installation and that there are
special notes for a RH installation, marked as ‘RH’, when modication of components is
required. All components included in the return unit are factory assembled for tting on
the LH side of the rail.
Follow the steps below to assemble the Trolley Return Unit 920/1500:
1. Remove the suction trolley stop from the rail, see ‘Figure 3’.
a) Drill holes for the motor unit brackets as illustrated.
RH: Drill holes on other side of suction trolley stop.
b) Fit and secure the Drive unit brackets on the suction trolley stop.
RH: Fit the supplied rubber stop extension according to ‘Figure 3’.
2. Fit and secure connection box 1 on the other side of the suction trolley stop, see
Figure 4. Use the supplied self-drilling and self-tapping screws.
3. Fit the suction trolley stop with connection box 1 on the suction rail, see Figure 5.
4. Fit and secure the drive unit in the brackets.
Figure 3
170 35
Rubber stop extension (RH)
130 24
Ø 6.5
Suction trolley stop
Vehicle travel direction
Figure 4
Self drilling and tapping screws
Figure 5

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5. Fit the limit switch SL4 on the rear of the drive unit as illustrated, see Figure 6.
6. Adjust the sensor so that the measurement ‘X2’ is 30 mm.
RH: Reposition fork.
7. Fit the guide pulley on the rail’s centre most mounting bracket, see Figure 7. If there
is a structure immediately above the guide pulley (a structure which can obstruct the
balls on the wire) a new hole for the guide pulley attachment must be drilled below
the existing hole in the bracket.
8. Fit the driving slot on the suction trolley, see Figure 8 item ‘a’.
(RH) Disassemble the driving slot rst and reassemble it according to Figure 8 item
‘b’.
NOTE! The supplied spacer washer must be used between suction trolley and angle
bracket.
Caution! Risk of equipment damage.
If the overload release screw is adjusted to contact with steel springs it will cause the
system to malfunction (due to a limit switch signal short circuit).
9. Check the adjustment of the overload release screw. The screw tip shall protrude 15
mm from plastic, but it can be adjusted if necessary, see Figure 8 item ‘b’.
Figure 6
SL4
X2
Vehicle travel direction
Figure 7
Figure 8
Driving slot
Spacer
Vehicle travel direction
a
Overload release screw
Spacer
b
b
a