Plymovent MER Operation instructions
www.plymovent.com
MER
Motorized Exhaust Hose Reel
0000110984/160920/A MER 2
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 anytime to
change or amendment, and the right to change or amend is hereby expressly reserved. Changes may be made with or without notication, it is the users
responsibility to ensure they have attained the most recent copy of this document for their les. 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.
0000110984/160920/A MER 1
TABLE OF CONTENTS
ENGLISH Page
Preface
1 Introduction 3
2 Product description 4
3 Safety 4
4 Installation 5
5 Pressure loss calculation 10
6 Electrical diagram 11
7 MER spare parts 13
0000110984/160920/A MER 2
GENERAL PRECAUTIONS
ATTENTION
Allow only qualied personnel familiar with adjustable
frequency AC drives, and associated machinery to
plan or implement the installation, start-up and
subsequent maintenance of the system. Failure to
comply can result in personal injury and/or equipment
damage.
ATTENTION
To avoid an electric shock hazard, verify that the
voltage on the bus capacitors has discharged before
performing any work on the electrical controls,
switches and/or drives if applicable.
ATTENTION
Incorrectly applied or installed electrical controls,
switches and/or drives can result in component
damage or a reduction in product life. Wiring or
application errors, such as, undersizing the motor,
incorrect or inadequate AC supply, or excessive
ambient temperatures can result in malfunction of the
system.
ATTENTION
The electrical controls, switches and/or drives may
contain ESD (Electrostatic Discharge) sensitive parts
and assemblies. Static control precautions may be
required when installing, testing, servicing or
repairing this assembly. Component damage can
result if ESD control procedures are not followed.
IMPORTANT USER INFORMATION
Read this document in entirety before you install, congure,
operate, or maintain this product. Users are required to
familiarize themselves with installation and wiring instructions in
addition to requirements of all applicable codes, laws and
standards.
Activities including installation, adjustments, putting into service,
use, assembly, disassembly, and maintenance are required to be
carried out by suitably trained personnel in accordance with
applicable code of practice.
If this equipment is used in a manner not specied by the
manufacturer, the protection provided by the equipment may be
impaired.
In no event will Plymovent be responsible or liable for indirect or
consequential damages resulting from the use or application of
this equipment.
The examples and diagrams in this manual are included solely
for illustrative purposes. Because of the many variables and
requirements associated with any particulate installation,
Plymovent cannot assume responsibility or liability for actual use
based on the examples and diagrams.
No patent liability is assumed by Plymovent with respect to use
of information, circuits, equipment, or software that may be
described in this manual. Throughout this manual, when
necessary, notes may be used to make you aware of safety
considerations.
The operation of exhaust extraction systems can be aected by
various factors including but not limited to proper design of the
system, operating procedures, service and maintenance. Fume
exhaust exposure levels should be checked upon installation and
periodically thereafter to ensure that they fall within applicable
regulations and exposure limit values.
Plymovent systems are made code compliant, please ensure the
system is properly designed, operated, serviced and maintained.
WARNING!
Identies information about practices or
circumstances that can cause an explosion in a
hazardous environment, which may lead to personal
injury, death, property damage, or economic loss.
ATTENTION
Identies information about practices or
circumstances that can lead to personal injury or
death, property damage, or economic loss. Attentions
help you identify a hazard, avoid a hazard, and
recognize the consequent.
IMPORTANT
Identies information that is critical for successful application
and understanding of the product.
SHOCK HAZARD
Labels may be on outside or inside of the equipment,
for example control box, to alert people that
dangerous voltage may be present.
ARC FLASH HAZARD
Labels may be on outside or inside of the equipment,
for example control box, to alert people to potential
Arc Flash. Arc Flash will cause severe injury or death.
Wear proper Personal Protection Equipment (PPE).
Follow ALL regulatory requirements for safe work
practices and for Personal Protective Equipment (PPE).
BE SURE THAT ALL INSTALLATION, OPERATION,
MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
0000110984/160920/A MER 3
PREFACE
Using this manual
This manual is intended to be used as a work of reference for
professional, well trained and authorized users to be able to
safely install, use, maintain and repair the product mentioned on
the cover of this document.
Pictograms and symbols
The following pictograms and symbols are used in this manual:
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.
WARNING!
Procedures which, if not carried out with the
necessary caution, may damage the product or cause
serious personal injury.
CAUTION!
Risk of electric shock.
WARNING!
Fire hazard! Important warning to prevent re.
Text indicators
Listings indicated by “-” (hyphen) concern enumerations.
Listings indicated by “•” (bullet point) describe steps to perform.
Service and technical support
For information about specic adjustments, maintenance or
repair jobs which are not dealt with in this manual, please
contact your Plymovent authorized distributor. To locate the
distributor for your area, visit www.plymovent.com and click
“Contact us,” then “Sales oces.”
1 INTRODUCTION
1.1 Identication of the product
The identication sticker on the hose reel, as shown in Fig. 1.2,
contains the following:
- product name
- serial number
- year in which hose reel was manufactured
1.2 General description
The Motorized Exhaust Hose Reel (MER) reduces the
occupational health risks from vehicle exhaust fumes and
enables the hose to be stored conveniently when not in use. MER
is designed for automobile, truck, bus and construction o-road
vehicle workshops with high ceilings and high-temperature
hoses.
The single phase version has a lifting capacity of 75 lbs and the
3 phase version has a lifting capacity of 110 lbs (50 kg).
1.3 Product combinations
This product is compatible with Plymovent fans, hoses, nozzles
and articulated boom arm.
1.4 Technical data
Here is an overview of MER components. MER also features
several options, such as motor output, hoses and lengths,
mechanical dampers, and direct mount fan.
Fig. 1.1 MER hose reel with hose
A. Hose reel drum provides a secure and space-friendly storage
location for the hose:
- smooth, zinc-plated drum on which the hose rolls;
- drum end plates are powder-coated yellow.
B. Console - zinc-coated steel frame provides support and
strength for longevity and robustness.
C. A-frame - primered and powder-coated steel.
D. Adapter Ø 6.3 in. (160 mm) to fan or central exhaust system.
E. Hose - not included.
F. Electrical junction box and motor - for landing wires and
connection of control equipment; includes a reliable self-
locking bevel gear drive, limit switches and thermal overload
protection.
Note: For North America, MER includes a 160 to 150 mm (6.25
to 6 in.) reducer to decrease the diameter of the hose
when making connections to standard 150 mm (6 in.)
ductwork.
Note: A standard, wall-mounted control box for up/down
operation is provided. Hanging pendant and wireless
controller options are available.
Fig. 1.2 MER identication sticker
A
E
B
C
F
D
0000110984/160920/A MER 4
1.4.1 Set the adjusting screw
During installation, installers must remove the motor cover and
using an allen wrench, set the start/stop hose position by
turning the adjusting screws on the three on/o limit switches
(A) in the gear box.
Fig. 1.3 Setting limit switches on MER
Note: An additional limit switch is available (B) to connect to a
Plymovent SA-24, ES-90 or DCV controller to be used as a
fan start signal.
Fig. 1.4 MER hose limit switches with switch for controller.
1.4.2 Max Hose Length
The maximum hose length that MER supports is dependent on
the specic version of MER hose reel ordered, the type and size
of the hose, and the type of the nozzle.
For example, up to 41 ft (12,5 m) of the HT-750 hose (6 in.
diameter) can be placed on MER. The table below demonstrates
the total weight of the Plymovent HT-750 hose and REGD nozzle.
Each system’s total weight will vary.
Component Weight
calculation Total weight
6 in. (150 mm) HT-750 Hose 1.15 lbs/ft
(1,71 kg/m) 47 lbs (21,3 kg)
Rubber nozzle REGD-150-160 4.4 lbs (2 kg) 4.4 lbs (2 kg)
Total weight of hose and nozzle 52 lbs (17,4 kg)
MER lifting capacity (Single Phase) 75 lbs (34 kg)
1.4.3 Power, Frequency, Motor Output, Motor Current
and Revs/min
Product no:
MER-XXX
Phase Power
Supply
(V)
Frequency
(Hz)
Motor
Output
hp
(kW)
Motor
Current
(A)
850/1050 1 120 60 0.75
(0.55)
7 - 7.5
850/1050 3 230/460 50/60 0.75
(0.55)
2.85 /
1.65
850/1050 3 230/460 50/60 0.75
(0.55)
2.85 /
1.65
1250 1 120 60 0.75
(0.55)
7 - 7.5
1250 3 230/460 50/60 0.75
(0.55)
2.85 /
1.65
1.4.4 Weight and lifting capacity
Product Weight
(lbs/kg)b
Lifting capacity
l(lbs/kg)
MER-850 1 Phase 137 (62 ) 75 (34)
MER-850 3 Phase 137 (62) 110 (50)
MER-1050 1 Phase 148 (67) 75 (34)
MER-1050 3 Phase 148 (67) 110 (50)
MER-1050-200 1 Phase 165 (75) 75 (34)
MER-1050-200 3 Phase 165 (75) 110 (50)
Refer to the available product data sheet for detailed
product specications.
1.5 Dimensions
Refer to Section 4.2 and 4.3 for dimensions and weights.
1.6 Transport of the unit
The manufacturer cannot be held liable for any transportation
damage after delivery of the unit. Always handle the unit and
the accompanying options and/or accessories, if any, with care.
MER is delivered with four mounting tabs/feet for wall or ceiling
mounting. The motor is tted with limit switches to control the
up/down positions.
Note: As an alternative to MER being connected to a ductwork
system, Plymovent fans FUA-1800, 2100 or 2700 can be
directly mounted to the hose reel. Hose, fan(s), starters
and tailpipe adapters must be ordered separately or with
Ø 6 in. (160 mm) hose for connection with a central
exhaust system. Hose and nozzle must be ordered
separately.
B
A
WARNING!
Remember to tighten the lock nuts on the adjusting
screws after setting the hose position, as vibrations
from the hose reel may loosen these nuts over time.
0000110984/160920/A MER 5
2 PRODUCT DESCRIPTION
2.1 Operation
Operating the hose reel is done by one of these up/down control
systems:
• Control Box with Up/Down push buttons
• Optional: hanging pendant
• Optional: wireless controller
No matter which controller is chosen, a button must be
depressed to uncoil and roll up the hose until the required
position (also known as the set limit) is reached.
Note: The two optional controllers listed above must be ordered
separately as an accessory.
WARNING!
Be careful when operating the hose reel so as to avoid
damage to persons and property.
3 SAFETY
General
The manufacturer does not accept any liability for damage to the
product or personal injury caused by ignoring 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.
Specic 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.
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.
- Never change the order of the steps to perform.
- Always keep the manual with the product.
Pictograms and instructions on the product (if
present)
- The pictograms, warning and instructions attached to the
product are part of the safety features. They must not be
covered or removed and must be present and legible during
the entire life of the product.
- Immediately replace or repair damaged or illegible pictograms,
warnings and instructions.
Users
The use of this product is exclusively reserved to authorized,
trained and qualied users. Temporary personnel and personnel
in training can only use the product under supervision and
responsibility of skilled engineers.
Intended use1
The product has been designed as a motorized hose reel to
extract exhaust gases. Using the product for other purposes is
1 “Intended use” as explained in EN-ISO 12100 is the use for which the technical
product is suited as specied by the manufacturer, inclusive of his directions in
the sales brochure. In case of doubt it is the use which can be deduced from the
construction, the model and the function of the technical product which is
considered contrary to its intended use. The manufacturer
accepts no liability for any damages or injury resulting from such
use. The product has been built in accordance with state-of-the-
art standards and recognized safety regulations. Only use this
product when in technical perfect condition in accordance with
its intended use and the instructions explained in the user
manual.
Technical specications
The specications given in this manual must not be altered.
Modications
Modication is not allowed.
Installation
- The installation of this product is exclusively reserved to
authorized, well-trained and qualied engineers.
- Inspect the product and check it for damage.
Verify the functioning of the safety features.
- Never install the product in front of entrances and exits which
must be used for emergency services.
- Make sure that the workshop, in the vicinity of the product,
contains sucient approved re extinguishers.
Tools
These tools are needed to install the MER system:
• Battery screw gun
• Screw drivers
• Misc hand tools and wrenches
• Allen wrench set
Please note that additional tools and machines may be needed
depending on the installation situation (installation height, space
available etc).
Use
- Check the working environment. Do not allow unauthorized
persons to enter the working environment.
- Protect the product against water and humidity.
- Use common sense. Stay alert and keep your attention to your
work. Do not use the product when you are under the inuence
of drugs, alcohol or medicine.
- Make sure the room is always suciently ventilated;
this applies especially to conned spaces.
considered normal use. Operating the machine within the limits of its intended
use also involves observing the instructions in the user manual.
0000110984/160920/A MER 6
Service, maintenance and repairs
WARNING!
Maintenance should only be performed by authorized,
qualied and trained persons (skilled) using
appropriate work practices.
4 INSTALLATION
WARNING!
Do not attempt installation of this unit unless you are
familiar with the necessary tools, equipment, utility
connections and potential hazards. Installation should
be performed only by a qualied service provider.
Failure to do so could result in reduced performance
of the unit, serious personal injury or death.
ATTENTION
The MER hose reel is delivered without cables for
external eld wiring. When using the MSR mircoswitch
all interconnect cables/wire size used shall comply
with the local requirements.
4.1 Assembly
To assemble the MER-850, MER-1050 and MER-1250, complete
the following steps:
• Dismantle drum lid.
• Mount MAP-kit (A) (except for 8 in (20 mm) hose reels, as
MAP-kit is not needed.
• Mount hose to the socket inside the drum using clamp (B).
• Bend hose into a natural soft curve and fasten it using clamp
(C).
• Re-mount the drum lid.
• Mount the edge protection (D) at the opening of the drum
where the hose protrudes.
• Start the motor, coil up the hose and set the limit switches
for up and down.
• Check the console holes to ensure they are set for the 6 in.
(150 mm) hole position (E), as shown in g. 4.1b. The
console provides multiple holes for Plymovent spring
operated hose reels, and these do not need to be adjusted
for MER.
Fig. 4.1a Hose reel assembly
Fig. 4.1b Console holes
4.2 MER reach and coverage
4.2.1 Reach and mounting height
A = Mounting height
B = Hose length
C = Max. reach
Measurements in ft. (m).
Hose length Mounting height Maximum reach
25 ft (7,5 m)
9.8 ft (3 m) 20.4 ft (6,2 m)
11.5 ft (3,5 m) 19.4 ft (5,9 m)
13.1 ft (4 m) 18 ft (5,5 m)
15 ft (4,5 m) 17.1 ft (5,2 m)
16.4 ft (5 m) 15.5 ft (4,7 m)
33 ft (10 m)
11.5 ft (3,5 m) 28 ft (8,5 m)
13.1 ft (4 m) 27.3 ft (8,3 m)
15 ft (4,5 m) 26.3 ft (8 m)
16.4 ft (5 m) 25.3 ft (7,7 m)
18 ft (5,5 m) 24.3 ft (7,4 m)
41 ft (12,5 m)
16.4 ft (5 m) 35 ft (10,6 m)
18 ft (5,5 m) 34 ft (10,3 m)
19.7 ft (6 m) 33 ft (10 m)
21.4 ft (6,5 m) 32 ft (9,7 m)
23 ft (7 m) 31 ft (9,4 m)
Fig. 4.2 Hose reel reach and mounting height
0000110984/160920/A MER 7
4.2.2 Dimensions
F
A
C
B
G
E
H
I
D
DIMENSIONS (NOMINAL)
MER-850 MER-1050 MER-1250-200
A40.5 in. (1030 mm) 48.4 in. (1230 mm) 56.3 in. (1430 mm)
B19.7 in. (500 mm) 19.7 in. (500 mm) 20.7 in. (525 mm)
C38.3 in. (974 mm) 46.2 in. (1174 mm) 54 in. (1374 mm)
DØ 6.3 in. (160 mm) Ø 6.3 in. (160 mm) Ø 8 in. (200 mm)
E31 in. (790 mm) 31 in. (790 mm) 44 in. (1117 mm)
F48.4 in. (1230 mm) 56.3 in. (1430 mm) 63.8 in. (1620 mm)
G23.6 in. (600 mm) 23.6 in. (600 mm) 28.9 in. (735 mm)
H21.7 in. (552 mm) 21.7 in. (552 mm) 22.7 in. (577 mm)
I19.3 in. (490 mm) 19.3 in. (490 mm) 23.4 in. (590 mm)
ATTENTION
When horizontally mounting a reel that contains either
a 6 in. or 8 in. (150 mm or 200 mm) hose, it is
recommended that you attach the hose so that it
rotates around the “front” of the hose reel drum (away
from the column or wall), as shown in Fig. 4.2.2c.
This will prevent the hose from scraping the horizontal
“console” bar, or colliding with any items attached to
the column or wall below the reel.
Fig. 4.2.2a Hose reel side view Fig. 4.2.2b Hose reel front view
Fig. 4.2.2c Hose rotating away
from column or wall
0000110984/160920/A MER 8
4.3 Adjusting the Limit Switches
1. Adjusting screw block
2. Set screw
3. ”Down” Limit switch
4. Limit switch lock nut
5. Adjusting screw
6. “Up” Limit switches
• Unroll the hose to desired position.
• Remove the motor case, then loosen the lock nut on the
threaded set screw (2). Adjust the set screw until you hear
the “Down” limit switch (3) click o.
• Wind up the hose to the preferred recoiled position.
• Adjust switch (4) with adjusting screw (5).
• Check and adjust desired position. A quarter turn on the
adjusting screw corresponds to 1 in. (24 cm).
• Make sure to tighten adjusting screws lock nuts (1). Then
adjust the “Up” limit switch (6) until on/o position
corresponds with switch.
4.4 Check MER terminal box wiring
Plymovent recommends you check the MER motorplate wiring.
Based on the model selected, the factory motorplate wiring will
be congured for 115V, 230V or 460V, as shown in g. 4.4b. The
terminal box plate will indicate “Delta” and “Y” symbol for 230V
and 460V, respectively.
Fig. 4.4a Example of MER terminal box wiring
4
3
16
5
2
Note: The “up” limit switch can be used for a fan start switch
when paired with a Plymovent SA-24/ES-90 or DCV
controller.
Fig. 4.3 MER limit switch illustration
Fig. 4.4b MER terminal box wiring diagram
0000110984/160920/A MER 9
4.5 Mounting options
4.5.1 Direct mount fan
MER includes ceiling or wall mounting feet as a standard. All
versions - except the 8 in. (200 mm) hose reel - can be tted
with a direct mount fan. Either for connection to a central
exhaust system or tted with a fan, as Fig. 4.5.1a through
4.5.1d explain. Follow these steps:
- Mount the fan with the reel upside down on the oor and then
mount the complete reel to its intended position.
- Attach bracket to reel (A)
- Fit rubber collar folded to socket (B)
- Screw fan to bracket (C)
- Unfold rubber collar over the reel’s socket (For North America
customers, a synthetic rubber-coated sleeve is applied) (D)
CAUTION!
Make sure the supporting structure on which the unit
will be mounted can handle the dynamic load
associated with the hose reel. Always consult a
structural engineer prior to installation, to ensure
compliance with all local codes.
4.5.2 Option: MER on articulated arm
Product
No.
Reach
mm (ft)
Max stretching/
bolt
kp (lbs)
Torque demands/
bolt
kp (lbs)
EB-3.5 3500 (11.5) 650 (1430) 1950 (4290)
EB-4.5 4500 (14.7) 900 (1984) 2700 (5940)
This option is not available for 8 in. (200 mm) hose reels. Follow
these steps to install the articulated arm:
- Bolt mounting bracket to wall or steel column
- Mount the fan (if included)
- Mount the extractor arm
- While attaching the reel and duct, set the friction by tightening
the bolt at swivel joint, until the arm remains in one position
- Mount hose reel to boom arm
- Mount spiro-tubing and hose on the extractor arm
- Mount ducting bend to hose reel, then mount the hose to the
ducting bend
- Re-adjust friction as needed
4.5.3 Factory-installed mechanical damper
Based on the facility design requirements, a sealed closing
damper will be factory installed on the
duct portion of the hose reel. In a facility
that includes multiple hose reels, this
built-in mechanical damper allows airow
only through the hose reel currently in
use, reducing energy costs. The damper
opens automatically when the hose is
lowered (2 rotations), and closes when
the hose is raised by the operator.
This damper is typically used when there
are no other dampers installed in the
duct work, and no electronic control units
are being installed. Fig. 4.5.3 Mechanical damper
Fig. 4.5.1a Inserting the DMF Bracket into the hose reel
Fig. 4.5.1b Inserting the DMF Bracket into the hose reel
Fig. 4.5.1c Tightening the bolts on the DMF bracket
Fig. 4.5.1d Mounting the operating springs on the hose reel drum
0000110984/160920/A MER 10
5 PRESSURE LOSS CALCULATION
The increase of pressure in a air duct system or in a hose is mainly determined by the air velocity in that system.
The higher the velocity is, the higher the pressure loss will be. And the higher the pressure loss is, the less air the fan will extract. Refer
to this manual’s Pressure Loss Calculation section for a Pressure Loss Chart to identify a suitable fan regarding the relationship between
airow (m3/h) and pressure loss (Pa).
In a ventilation system with many extraction devices and long suction ducts, you can minimize pressure loss by increasing the size of the
ducting.
Note: We recommend that the facility’s current exhaust temperatures are conrmed to ensure proper hose, fan and airow selection.
Fig 5.1 shows the pressure loss in the hose reels at dierent diameters and length. The curves in this chart show the following
combinations of hose diameter and hose length. The curves show these combinations of hose reel/hose diameter/hose length:
A Ø 100 mm (4 in.) length 7.5 m ( 24,7 ft)
B Ø 100 mm (4 in.) length 10 m ( 32,8 ft)
C Ø 100 mm (4 in.) length 12.5 m (41,1 ft)
D Ø 125 mm (5 in.) length 7.5 m (24,8 ft)
E Ø 125 mm (5 in.) length 10 m (32,8 ft)
F Ø 125 mm (5 in.) length 12.5 m (41,1 ft)
G Ø 150 mm (6 in.) length 7.5 m (24,7 ft)
H Ø 150 mm (6 in.) length 10 m (32,8 ft)
I Ø 150 mm (6 in.) length 12.5 m (41,1 ft)
J Ø 200 mm (8 in.) length 10 m (33 ft)
Note: 75 mm (3 in.) hoses are not available in North America.
A
B
C
D
E
F
G
H
I
J
Fig. 5.1 Pressure loss by hose
diameter and length
0000110984/160920/A MER 11
6 ELECTRICAL DIAGRAM
MER 230V/460V 3 Phase Wiring
Note: Make sure the transformer in the MER Control Box is wired for 230V or 460V.
0000110984/160920/A MER 12
6 ELECTRICAL DIAGRAM
MER 120V Single Phase Wiring
0000110984/160920/A MER 13
7 MER SPARE PARTS LIST
How to Order Spare Parts:
At this time, Plymovent is reviewing spare parts for this hose reel. Please contact your authorized distributor to discuss the spart that
you need. You can identify your authorized distributor at https://www.plymovent.com - click the “Contact Plymovent” link and then click
“Sales Oces.”
www.plymovent.com
10340/290119/B MER
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3
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