Plymovent 200 Series User manual

www.plymovent.com
EN Installation and user manual for balancer-200, -300 and -350
BALANCER-200 & 300 SERIES

0000117916/221118/A Balancer-200 and -300 series
2
ENGLISH Page
Preface 3
1. Introduction 3
2. Product description 4
3. Safety instructions 4
4. Installation 5
5. Use 6
6. Maintenance 6
7. Troubleshooting 6
8. Spare parts 7
9. Disposal 7
CE declaration 7
EN – ORIGINAL INSTRUCTION
All rights reserved. The information given in this document has been collected for the general convenience of our clients. It has been based on general data pertaining to construction material
properties and working methods known to us at the time of issue of the document and is therefore subject at any time to change or amendment and the right to change or amend is hereby expressly
reserved. The instructions in this publication only serve as a guideline for installation, use, maintenance and repair of the product mentioned on the cover page of this document. This publication is to
be used for the standard model of the product of the type given on the cover page. Thus the manufacturer cannot be held responsible for any damage resulting from the application of this publication
to the version actually delivered to you. This publication has been written with great care. However, the manufacturer cannot be held responsible, either for any errors occurring in this publication or
for their consequences.
To improve comprehension for people whose rst language is not English, we have written parts of this manual in Simplied Technical English (STE). STE is a controlled language
originally developed for aerospace industry maintenance manuals. It offers a carefully limited and standardized subset of English, along with specic writing rules.
TABLE OF CONTENTS

0000117916/221118/A Balancer-200 and -300 series EN - 3
PREFACE
Using this manual
Pictograms and symbols
The following pictograms and symbols are used in this manual:
TIP
Suggestions and recommendations to simplify
carrying out tasks and actions
ATTENTION
A remark with additional information for the user. A
remark brings possible problems to the user’s
attention.
CAUTION!
Procedures, if not carried out with the necessary
caution, could damage the product, the workshop or
the environment.
Text indicators
Listings indicated by “-” (hyphen) concern enumerations.
Listings indicated by “•” (bullet point) describe steps to
perform.
Service and technical support
For information about specic adjustments, maintenance or
repair jobs which are not dealt with in this manual, please
contact the supplier of the product. He will always be willing to
help you. Make sure you have the following specications at
hand:
- product name
- serial number
You can nd these data on the identication plate.
Product indications
Unless specically stated, the contents of this manual applies
to the balancer-200, -300 and -350 series.
1 INTRODUCTION
1.1 Identication of the product
The identication plate contains, among other things, the
following data:
- product name
- serial number
1.2 General description
Balancer to hold and lift the hose of a vehicle exhaust system.
The integrated safety wire is to be attached to the system’s
trolley or mounting device. The BRL types contain an
additional lock.
1.3 Technical specications
1.3.1 Balancers
Balancer
BR-200/8-
17
Balancer
BR-300/7-
14
Balancer
BR-350/5-
14
Article no. 0000100363 0000100364 0000104951
Wire length 2 m
(6.5 ft.)
3 m
(10 ft.)
3,5 m
(11.5 ft.)
Spring
tension
8-17 kg
(18-37 lbs)
7-14 kg
(15-31 lbs)
5-14 kg
(11-31 lbs)
Angle from
plumb line
max. 45° max. 45° max. 45°
1.3.2 Balancers with lock
Balancer
BRL-300/7-17
Balancer
BRL-350/5-14
Article no. 0000100366 0000100367
Wire length 3 m
(10 ft.)
3,5 m
(11.5 in.)
Spring
tension
7-17 kg
(15-37 lbs)
5-14 kg
(11-31 lbs)
Angle from
plumb line
max. 45° max. 45°
Refer to the available product data sheet for
detailed product specications.
1.4 Scope of supply
Standard, all balancers are delivered without the balancer
locking cable. The balancer locking cable can be ordered
separately or is delivered with following kits:
Description Art. no.
ICCA-100 0000113864
ICCA-125 0000113869
ICCA-150 0000113751
IC-100 0000109783
SBT-KIT 0000105160
Balancer locking cable 0000105126

0000117916/221118/A Balancer-200 and -300 series EN - 4
2 PRODUCT DESCRIPTION
2.1 Product components
The product consists of the following main components and
elements:
Fig. 2.1
A re brigade snap hook Ø 8 mm (5/16 in.)
B spring tension lock
C balancer locking cable (optional)
D balancer wire stop
E wire
F re brigade snap hook Ø 8 mm (5/16 in.)
G safety wire
H balancer body including spring
Fig. 2.1 Main components
3 SAFETY INSTRUCTIONS
General
The manufacturer does not accept any liability for damage to
the product or personal injury caused by ignoring of the safety
instructions in this manual, or by negligence during installation,
use, maintenance, and repair of the product mentioned on the
cover of this document and any corresponding accessories.
Specic working conditions or used accessories may require
additional safety instructions. Immediately contact your supplier
if you detect a potential danger when using the product.
The user of the product is always fully responsible for
observing the local safety instructions and regulations.
Observe all applicable safety instructions and regulations.
User manual
- Everyone working on or with the product, must be familiar
with the contents of this manual and must strictly observe
the instructions therein. The management should instruct the
personnel in accordance with the manual and observe all
instructions and directions given.
- Do not change the order of the steps to perform.
- Keep the manual with the product.
Users
- The use of this product is exclusively reserved to authorised,
trained and qualied users. Temporary personnel and
personnel in training can only use the product under
supervision and responsibility of skilled engineers.
- Stay alert and keep your attention to your work. Do not use
the product when you are under the inuence of drugs,
alcohol or medicine.
- The product is not to be used by children or persons with
reduced physical, sensory or mental capabilities, or lack of
experience and knowledge, unless they have been given
supervision or instruction.
- Children must be supervised not to play with the product.
Technical specications
Do not change the specications given in this manual.
Modications
Modication of (parts of) the product is not allowed.
Installation
- The installation of this product is exclusively reserved to
authorised, trained and qualied engineers.
- During installation, always use Personal Protective
Equipment (PPE) to avoid injury. This also applies to persons
who enter the work area during installation.
- Use sucient climbing gear and safety guards when working
on a higher level than 2 metres (6 ft. OSHA) (local restrictions
may
apply).
- Do not install the product in front of entrances and exits
which must be used for emergency services.
- Mind any gas and water pipes and electric cables.
- Make sure that the workspace is well illuminated.
- Stay alert and keep your attention to your work. Do not
install the product when you are under the inuence of
drugs, alcohol or medicine.
Use
- Inspect the product and check it for damage. Verify the
functioning of the safety features.
- Check the working environment. Do not allow unauthorised
persons to enter the working environment.
- Protect the product against water and humidity.
- Make sure the room is always suciently ventilated; this
applies especially to conned spaces.
- Make sure that the workshop, in the vicinity of the product,
contains sucient approved re extinguishers (suitable for
re classes ABC).
Service, maintenance and repairs
- Obey the maintenance intervals given in this manual.
Overdue maintenance can lead to high costs for repair and
revisions and can render the guarantee null and void.
- Always use Personal Protective Equipment (PPE) to avoid
injury. This also applies for persons who enter the work area.
- Make sure the room is suciently ventilated.
- Use tools, materials, lubricants and service techniques which
have been approved by the manufacturer. Never use worn
tools and do not leave any tools in or on the product.
- Use sucient climbing gear and safety guards when working
on a higher level than 2 metres (6 ft. OSHA) (local
restrictions may apply).
- Clean the area afterwards.
A
B
C
D
F
G
H
E

0000117916/221118/A Balancer-200 and -300 series EN - 5
4 INSTALLATION
4.1 Tools and requirements
The following tools and requirements are needed to install the
product:
- wrench 8 mm (5/16 in.)
- power cutter
- socket 24 mm for BR-200/300
(0000115762 set of 5, not in scope of supply)
4.2 Mounting
The balancer can be mounted to the following devices:
- trolley of SBT system
- trolley of STR system
- VSR
- drops
4.2.1 Mounting to the trolley of SBT system
• Mount the re brigade snap hook Ø 8 mm (5/16 in.) to the
balancer and the trolley.
• Mount the safety wire to the trolley and fasten with a M8 x
20 bolt and 8 mm hex nut and washers.
• Mount the re brigade snap hook Ø 8 mm (5/16 in.) to the
balancer and the elbow.
• Mount the balancer locking cable to the trolley and the
balancer. Please refer to paragraph 4.3 for the mounting of
the balancer locking cable.
Fig. 4.2.1 Mounting balancer to SBT system
4.2.2 Mounting to trolley of STR system
Fig. 4.2.2 Mounting balancer to STR system
• Mount the re brigade snap hook Ø 8 mm (5/16 in.) to the
balancer and the trolley.
• Mount the safety wire to the trolley and fasten with a M8 x
20 bolt and 8 mm hex nut and washers.
• Mount the re brigade snap hook Ø 8 mm (5/16 in.) to the
balancer and the elbow.
• Mount the balancer locking cable to the trolley and the
balancer. Please refer to paragraph 4.3 for the mounting of
the balancer locking cable.
4.2.3 Balancers used in drops
Drops have no provision to mount the safety wire.
Instead it can be mounted to the wall or ceiling contruction,
e.g. by means of a mounting plate.
• Mount the balancer to the drop in question.
• If desired, attach the safety wire to the wall or ceiling
construction.
CAUTION
Make sure the safety wire connection is strong
enough to hold the weight of the entire
conguration.
4.3 Balancer locking cable
The locking cable’s primary function is to control the point of
disconnection.
As the hose reaches it’s maximum length the balancer locking
cable will bottom out, in turn pulling the nozzle from the
moving vehicle.
To enable this function it is necessary to cut the locking cable
to the appropriate length by performing the following steps:
• Extract the nozzle up to 25 cm +/- 5 cm (10 in. +/- 2 in.)
from the door and 50 cm (20 in.) from the ground (tailpipe
height).
• Measure the shortest distance between the two spring
safety hooks of the balancer.
• Cut the balancer locking cable using a power cutter and
adjust to the measured distance.
• Install the balancer locking cable between the two spring
safety hooks.
4.4 Functioning and setting
The balancer is factory-wise delivered with a pre-tension.
It needs to be adjusted to its nal tension when the entire
installation is ready. Depending on the installation, there are
two possibilities:
- pre-tension is OK
- spring tension needs to be increased
Check if the balancer is capable of holding and lifting the
connected hose. If not, increase the spring tension as follows:
• Hold the balancer steady.
• Turn casing cap max. 0,5 revolutions clockwise (direction
+) using a socket 24 mm
CAUTION
Do not increase spring tension more than 0,5
revolution to avoid serious damage to the balancer.
Except for the BR-200 / 8-17 which can be
increased up to 1 revolution.

0000117916/221118/A Balancer-200 and -300 series EN - 6
5 USE
The balancer is used to keep the exhaust extraction hose clear
of the ground, thus minimising the risk of damage to the hose
and surroundings. It also enables easy operation of the
exhaust extraction system.
6 MAINTENANCE
6.1 Periodic maintenance
The product has been designed to function without problems
for a long time. In order to guarantee this some simple, regular
maintenance activities are required which are described in this
chapter.
The maintenance activities in the table below can be carried
out by the user.
Component Action Frequency:
every X months
X=6 X=12
Housing Check for crack
and loose screws.
Replace balancer
when housing
shows cracks.
X
Wire Check wire for
visible damage
e.g. broken
threads. Replace if
necessary.
X*
* Before every use
6.2 Replacing the wire
WARNING!
The balancer contains a powerful spring. Remove
the tension from the balancer before opening.
• Use a 24 mm socket to apply a bit of tension on the spring.
• Carefully release the spring tension lock and remove
tension from the balancer per quarter turn and lock again.
Repeat until the balancer is freed of tension.
• Open the circlip (A) of the balancer with a circlip pliers.
• Pull out the cover of the balancer.
• Remove the wire by removing the nut and washer (B).
• Replace wire and x with nut and washer.
• Place the wire spool back in the balancer and put the cover
back on.
• Secure with the circlip.
• Put tension back on the balancer and secure with the
spring tension lock.
Fig. 6.2 Exploded view
7 TROUBLESHOOTING
Problem Possible cause Solution
Wire is not
retracted when
nozzle is
disconnected.
Spring tension too
low.
Increase spring
tension. Refer to
section 4.4
(Functioning and
setting).
Spring is broken. Replace balancer.
Vehicle exhaust
system
disconnects too
quick from tail
pipe.
Spring tension too
high.
Decrease spring
tension. Refer to
section 4.4
(Functioning and
setting).
The locking cable
is too short.
Replace locking
cable.
The kickback of
the hose drop
after disconnection
is too powerful.
Spring tension too
high.
Decrease spring
tension. Refer to
section 4.4
(Functioning and
setting).
A
B

0000117916/221118/A Balancer-200 and -300 series EN - 7
8 SPARE PARTS
Position Article number Description
• Balancer BR-200/8-17
1 0000105126 Balancer locking cable
2 0000117920 Spring tension lock
BR200/300 (set of 5)
3 0000114654 Wire complete 2m
• Balancer BR-300/7-14 & Balancer BRL-300/7-17
1 0000105126 Balancer locking cable
2 0000117920 Spring tension lock
BR200/300 (set of 5)
3 0000114390 Wire complete 3m
• Balancer BR-350/5-14 & Balancer BRL-350/5-14
1 0000105126 Balancer locking cable
1 0000117920 Spring tension lock
BR200/300 (set of 5)
3 0000114389 Wire complete 3,5m
Fig. 8 Spare parts
9 DISPOSAL
After life of the product, dispose it of in accordance with
federal, state or local regulations.
CE DECLARATION
CE declaration of conformity for machinery
We, Plymovent, Koraalstraat 9, 1812 RK Alkmaar, the
Netherlands, herewith declare, on our own responsibility, that
the product(s):
- Balancer
which this declaration refers to, is/are in accordance with the
conditions of the following Directive:
- 2006/42/EC
and is/are in conformity with the following harmonized
standard(s) and/or other such normative documents +
amendments, if any:
- DIN 15112
Alkmaar, the Netherlands, November 22nd, 2018
Kees Janssen
Product Manager EE

www.plymovent.com
0000117916/221118/A Balancer-200 and -300 series