Nederman Pneumatic Track System User manual

PTS
144265(04)
2010-12-17
EXHAUST EXTRACTION
INSTRUCTION MANUAL
Pneumatic Track System
Track length 38 ft 9 in (11,8 m)

PTS
2
Alternative 1
1 ft 4 in - 2 ft
(0,4 - 0,6 m)
min. 1 ft
(0,3 m)
1 ft 4 in - 2 ft
(0,4 - 0,6 m)
min. 1 ft
(0,3 m)
Alternative 2
10 - 13 ft (3 - 4 m) 11 ft 6 in (3,5 m) recommended
10 - 13 ft (3 - 4 m) 11 ft 6 in (3,5 m) recommended
A
~ 3 ft (1 m)

PTS
5 in
(0,15 m)
6 ft
(1,8 m)
7 ft 9 in
(2,35 m)
6 ft 8 in
(2,05 m)
7 ft 9 in
(2,35 m)
8 ft 2 in
(2,50 m)
2 ft
(0,6 m)
1
Alternative 1
Alternative 2
exit
3
3
292 lbs (1300 N)
292 lbs
(1300 N)
AB
C
D
292 lbs (1300 N)
292 lbs
(1300 N)
292 lbs
(1300 N)
E
1
2

PTS
4
Alternative 2
4
exit
4
5
7
19 ft 4 in (5,9 m)
Alternative 1
8
6
exit
Secondary track
Main track

PTS
10
10
11
14
9 a - e
min. 7 ft (2,1 m)
Vehicle in parking position
87 – 116 psi
(6 – 8 bar)
exit
X
Disconnection
valve
Compressed
air pressure
regulator
12 ft 6 in
(min. 3,8 m)
13
ABC
1/6 in
(Ø 4,5 mm)
exit
5
min. 1 ft 8 in
(0,5 m)
12

PTS
6
Diagram for
compressed air
B
min. 12 in (300 mm)
min. 4 in (100 mm)
min. 4 in (100 mm)
min. 12 in (300 mm)
min. 4 in (100 mm) min. 2 in (50 mm)
min. 4 in (100 mm)
min. 2 in (50 mm)
C
min. 2 in (50 mm)
D
Disconnection valve
Nozzle kit
Air vent Pneumatic nozzle
Manual valve
Pressure regulator
Pilot signal
1 bar (14,5 psi)
6-8 bar (87-116 psi)
87-116 psi (6-8 bar)
14,5 psi (1 bar)

PTS
WARNING!
Risk of personal injury!
When mounting the PTS system, check
that the system will not snag protruding parts
on the vehicle when driving in or out.
7
Foreword
To ensure the correct performance, it is important
to read and understand the information in this
instruction manual.
To maintain the status, installation, repair and
maintenance work must be carried out by qualied
personnel using only original spare parts. Contact
your nearest authorized 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 product:
- Pneumatic Track System (PTS) with accessories to
which this declaration relates, are in conformity with
the following:
Directives
2006/42/EC
Standards
EN ISO 12100-1-2
The product manager, Roger Knutsson, is responsible
for the technical documentation.
AB Ph. Nederman & Co.
P.O. Box 602
SE-251 06 Helsingborg
Sweden
Roger Knutsson, Product Manager
Technical data
Mounting height............................................10-13 ft (3-4 m)
11 ft 6 in (3,5 m) recommended
Track length...............................................38 ft 9 in (11,8 m)
Material, track......................................................Aluminium
Compressed air connection...................87-116 psi (6-8 bar)
Compressed air in the system......................14,5 psi (1 bar)
WORK SAFETY REGULATIONS
WARNING! Risk of personal injuries
and/or product damages.
• The system must not be used for other pur-
poses than extracting exhausts from apparatus.
• The system is designed for emergency
response applications only. Any other usage
is strictly prohibited and could void the warranty
of the system.
• The system must not be used when working on
the vehicle´s fuel system or whenever there is a
risk of inammable dust or explosive gases.
• The system is designed for use only in the exit
direction of the length of the track.
• Check that there is enough suction capacity
in the exhaust hose before it is connected to the
vehicle exhaust pipe. Check the fan impeller rota-
tion direction and/or damper function.
• Check that the hose or nozzle will not snag on
any protruding parts on the vehicle.
• Do not extract hot, burning or ignited material
or substances that might react with parts or
materials from the suction system.
• Regeneration is not allowed when the exhaust
extraction system is attached to the tail pipe.
•Risk of high temperatures! Use protective
gloves or avoid contact with the hose or nozzle
after the system has been used.

PTS
8
A lockable safety switch is recommended for
the electrical system including the fan.
Before installation
Before the PTS system can be installed, a suitable
position must be determined in relation to the vehicle's
parking position in the station. N.B. The vehicle’s par-
king position must be on the opposite side
of the track compared to the duct connection.
See picture Alternative 1 / 2.
The distance from the oor to the bottom edge of the track
should normally be 10 - 13 ft (3 - 4 m). 11 ft 6 in (3,5 m)
is recommended. If the system is to be used between two
vehicles, the distance between the vehicles must be at
least 4 ft (1,2 m).
The distance from the track's front edge to the station
door threshold should be at least 3 ft (1,0 m). Make
sure the door can open freely without interference to
the track. See picture A.
Installation instructions
See pictures 1 - 14.
1. Place all the track proles in line with each other
on the oor according to the picture. Screw the proles
together with the lengthening joints.
2. Fasten the mounting brackets on the proles
according to the measurements in the picture.
3. Lift the tracks and t them in the ceiling. Check that
there is no gap between the track sections. The
mounting devices should be xed in bars, brackets or
similar arrangements according to the examples.The
rst and the last mounting bracket should be braced
(see pictures Aand B). All mounting brackets should
be braced with bracing bars positioned sideways ac-
cording to one of the pictures C,D or E. When moun-
ting the track, ensure that suitable xing bolts are used
considering the ceiling construction material and the
traction forces in the suspension points.
4. Position the duct connector near the middle of the
main track. Fasten it according to 12 a - e. NB! The
duct connector must not be positioned on the
same side of the track as the vehicle's parking
position (see picture Alternative 1 / 2).
5. Connect the nozzle kit on the safety
coupling.
6. Slide the trolley with balancer into the main track.
7. Fit the balancer cord in the sheet metal bend.
8. Mount the trolley with hose holder in the
secondary track. Fit the hose holder on the hose
minimum 12 ft 6 in (3,8 m) from the balance cord (see
picture 9).
The exhaust hose length is delivered for a mounting
height of 11ft 6 in (3,5 m). It is important that
the nozzle suspends freely (approx. 1 ft (30 cm))
from the oor when the hose is in its raised
position. For higher mounting heights than 11 ft 6 in
(3,5 m) the hose position is adjusted by moving the
balancer cord stop the necessary length. For lower
mounting heights than 11 ft 6 in (3,5 m) the exhaust
hose must be cut in the following way:
a. Separate the safety coupling.
b. Close the compressed air supply.
c. Cut o the necessary length of the lower
exhaust hose.
d. Cut the compressed air hose by the same length
as the exhaust hose.
e. Reassemble the hose and the safety coupling.
f. Check that there is no tension in the hose after
the nozzle has been connected to the exhaust pipe.
9. To obtain clearance height under the exhaust
hose (when the vehicle is in parking position) the
position of the duct connector must be adjusted in
the following way (see picture 9 a - e):
a. Back the vehicle into its parking position.
b. Slide the exhaust nozzle onto the exhaust pipe
of the vehicle.
c. Loosen the duct connector from the exhaust track
and push it towards the door opening and the track´s
front edge, until the distance from the oor to the bottom
edge of the exhaust hose is at least 7 ft (2,1 m).
d. Drill holes, diameter 2/5 in (10 mm) in the track
for the duct connector bracket. It is to be noted that
the duct connector must be fastened in front of the
middle of the track.
e. Fasten the duct connector with screws.
10. Install shock absorbers in the front edge of the tracks.
11. Install screw and nut at the back edge of the tracks.
12. Install the disconnection valve on the front part
of the main track. Install the valve with the screw X.
Max. moment = 1,1 lbft (1,5 Nm). The exact distance
from the front edge of the track must be checked acc.
to the installation protocol point 3F.
13. Install the compressed air hose to the T-coupling.
The hose is mounted on the top of the guide track. Drill
holes, 1/6 in (4,5 mm) diameter, and t the hose with
clips according to the pictures. Adjust the hose length
and connect the hose to the disconnection valve.
14. A exible hose, minimum length 1 ft (30 cm) must
be connected between the duct connector and the
duct pipe work.
Fans
Fans are not included in the basic package. For the
best results, one fan per extraction unit is recom-
mended. It is also possible to connect several units
to a central fan.
To obtain optimum performance, the fan should be
positioned as near the duct outlet from the room as
possible. Please contact your Nederman represen-
tative for advice on fan selection.
The exhaust pipe
The edge of the exhaust pipe must have a free
distance to surrounding vehicle parts. See recom-
mendations, picture C. Check that the nozzle, after the
disconnection, does not catch any part of the vehicle.
It is possible that modications may be required to the

PTS
User instruction, disconnection
1. Make sure the nozzle is connected to the exhaust
pipe.
2. Start the fan and open the station door. Drive the ve-
hicle straight out from the garage. The nozzle automa-
tically disconnects when the vehicle is driven out.
A manual disconnection is possible with the switch
on the safety coupling (see picture above).
Spare parts
See www.nederman.com
When ordering parts always state:
• Part no. and control no.
(see type label of the product)
• Name of the spare part.
• Quantity of the parts required.
Parts subject to wear are:
- Exhaust hose
- Safety coupler
- Nozzle
Safety coupling
The system is equipped with a safety coupling which
disconnects the hose if the nozzle for some reason
does not disconnect from the exhaust pipe when the
vehicle exits from the station. The disconnection force
is factory set to 112 lbs (500 N).
Before reattaching the safety coupling, pull the release
cord on the hose just above the safety coupling. A
manual disconnection is also possible by pulling the
release cord.
9
User instruction, connection
1. Open the station door and start the exhaust
extraction fan (as an option the system has
automatic fan start).
2. Position the vehicle so that the exhaust pipe
is just at the station door (see picture A).
3. Deate the nozzle by
using the switch on the
safety coupling. Connect
the nozzle to the exhaust
pipe. Inate the nozzle
with air by using the switch.
4. Back the vehicle into
its parking space.
The hose with nozzle
should always be con-
nected to the exhaust pipe while the
vehicle is parked in the station.
exhaust system to ensure the optimum position of the
exhaust pipe.
Recommended nozzle diameter to the exhaust pipe:
2 – 3 1/3 in (50 – 85 mm) for the 5 in (125 mm) nozzle
2 3/4 – 5 in (70 – 125 mm) for the 6 1/3 in (160 mm) nozzle
4.9 – 7 in (125-180 mm) for the 8 in (203 mm) nozzle.
The tail pipe stop
A tail pipe stop is mandatory.
The tail pipe stop should be assembled according to
instruction enclosed in the package of the product.
Compressed air connection
See diagram for compressed air, picture D.
Disconnect the nozzle kit.
Make sure that the existing compressed air
piping is clean and connect compressed air,
87 – 116 psi (6 – 8 bar), to the system.
Adjust the manometer on the compressed air
pressure regulator (see picture page 5) to 14,5
psi (1 bar). Reconnect the nozzle kit.
The pneumatic components must only be
used with ltered compressed air. Use water
and oil separator with automatic draining and
air ltration according to DIN ISO 8573-1,
class 5/5/4.
Switch for
ination and
deation of
nozzle
Safety
coupling
release
6 in (152 mm)
4 in (101 mm)

PTS
INSTALLATION AND MAINTENANCE PROCEDURE
The system is ready for use after checking the control points according to this protocol.
Check the points 3A – 3P at least twice a year or when necessary.
1. Fan
A. Designation, article and control no.
B. Current
C. Voltage and phase
D. Safety switch (local regulations)
2. Pressure switch and Fan Control
A. Pressure Switch, article no. / control no.
B. Fan Control Manual, article no. / control no.
C. Check that Pressure Switch and Fan Contactor
are installed correctly according to wiring diagram
in manual 148882.
D. Check the motor protector settings in the Fan
Contactor according to installed fan motor.
3. Functional test
A. Check the compressed air connection. Adjust the
manometer on the compressed air pressure regula-
tor (see picture on page 5) to 14,5 psi (1 bar) before
the nozzle kit is connected.
B. Check that the nozzle will discharge the com-
pressed air and disconnect from the exhaust pipe
when the trolley has passed the disconnection
valve. If not, check the following:
a. The air valve on the nozzle. Check that air
discharges when the nozzle disconnects.
b. The manometer on the compressed air pressure
regulator (see picture on page 5) must be set on
maximum 14,5 psi (1 bar). Adjust if necessary.
c. The position of the disconnection valve at right
angles to the track may be in need of an adjust-
ment. Check functioning.
Result Result Note
Date
Performed by
PTS Article no. / Control no.
Control points
Operating hours
10

PTS
11
3. Functional test (continued)
C. Note the Fan Start Pressure Switch setting. If
necessary adjust the activating pressure on the
pressure switch (see manual 148882).
D. Connect the system to the vehicle and check
that the fan starts when the engine is started.
Otherwise adjust the Pressure Switch.
E. Check that the nozzle gets compressed air after
the disconnection from the exhaust pipe.
F. Check the disconnection procedure.The
nozzle should disconnect from the exhaust pipe
immediately before the station door threshold.
Adjust the disconnection position by moving the
disconnection valve on the front track. Fit the valve
with the screw X(see picture 12).
G. Check the air ow in the nozzle opening with
an air ow indicator. Check, if necessary, the fan
impeller rotation direction and/or damper function
in the duct connector.
H. Check that the hose falls away in a steady and
even manner after disconnection. The balancer
should gently return the hose to its rest position.
When required, adjust the balancer lifting power.
J. Check the operation of the safety coupling.
Check that it is possible to draw it apart by a force
of approximately 112 lbs (500 N) (= solid hand
force, see picture B). Clean and grease the safety
coupling if necessary. If the operation is not
correct, please contact a Nederman representative
for technical advice.
Make sure the compressed air hose has enough
slack to cope with the hose stretching without bee-
ing pulled out of the safety coupling valve nipples.
K. Check that the hose and the nozzle do not inter-
fere with any part of the vehicle or the station door.
L. Check the trolley regarding wear and check that
it moves the whole length of track.
M. Check the mounting devices.
N. Check the balancer according to the balancer
manual.
O. Check the hoses for damage and wear.
P. Check that the nozzle is attached to the exhaust
pipe. Also check the nozzle, exhaust pipe and tail
pipe stop position for damage, wear and correct
position.
Result Result Note
Date
Performed by
PTS Article no. / Control no.
Control points
Operating hours

PTS
Nederman is represented in:
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Germany, Greece, Hong Kong, Hungary, Iceland, India, Iran, Ireland, Italy, Japan, Korea, Latvia, Lithuania, Malaysia, the Netherlands, Norway,
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Switzerland, Taiwan R.O.C., Thailand, Turkey, United Arab Emirates, United Kingdom, USA.
www.nederman.com