Pneumatic Rail System, PRS

No. 142595 / 01 2009-09-28

Exhaust extraction system for vehicles in motion

EXHA

UST R

AIL

INSTRUCTION MANUAL GB

AAB072

PRSPRS

22

GB

Contents:Declaration of Conformity . . . . . . . . . . . . . . . 3Mounting Instructions . . . . . . . . . . . . . . . . . . . 4

General application. . . . . . . . . . . . . . . . . . . . . . . 4Emergency application. . . . . . . . . . . . . . . . . . . . 4

Installation Instructions . . . . . . . . . . . . . . . . . 6Mounting of rail . . . . . . . . . . . . . . . . . . . . . . . . . . 6Inserting trolley(s) in rail . . . . . . . . . . . . . . . . . . . 6Mounting of several suction trolleys. . . . . . . . . . 6 Mounting of suspension wire for compressed-air hose spiral. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Adjustment of exhaust rail . . . . . . . . . . . . . . . . . 8Connection of exhaust extraction nozzle to exhaust pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Connection of extra shock absorber . . . . . . . . . . . 10

Safety coupling . . . . . . . . . . . . . . . . . . . . . . . 10Locking system . . . . . . . . . . . . . . . . . . . . . . . 10Fan connection . . . . . . . . . . . . . . . . . . . . . . . . 11Installation inspection/Service . . . . . . . . . . 12Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

FlexFilter DXPRS

33

GB

ForewordTo guarantee a correct function and minimal service, it is important to read and understand the information in this instruction manual. 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 conformityWe, AB Ph. Nederman & Co., declare under our sole re-sponsibility that the product Pneumatic RailSystem, to which this declaration relates is in confor-mity with the following standards or other legislative documents: EN ISO 12100-1 and EN ISO 12100-2 and following the provisions of Directives 98/37/EC, 94/9/EC.

AB Ph . Nederman & Co . P.O. Box 602SE-251 06 Helsingborg Sweden

Technical dataMounting height...........................................10-16 ft (3-5 m) 13 ft (4 m) recommendedTrack length...............................................max 114 ft (35 m)Hose diameter.................................................4 ft (100 mm)Hose length....................................................16 ft 5 in (5 m) + 3 ft (1 m)Material, rail...........................................Aluminium + EPOMCompressed air feed.............................87-116 psi (6-8 bar)Compressed air, system pressure.................14.5 psi (1 bar)

For detailed technical data, see technical leaflet.

Roger Knutsson, Product Manager

WORK SAFETY REGULATIONSWARNING! Risk of personal injuries and/or product damage .• The system must not be used for other purposesthan extracting exhaust gases.• The system must not be continously exposedto higher temperature than the stated designtemperature.• The system must not be used when working onthe vehicle's fuel system or whenever there is a risk of inflammable dust or explosive gases.• The system is designed for use only in the exitdirection of the length of the track.• Check that there is enough suction capacity inthe exhaust hose before it is connected to thevehicle exhaust pipe. If needed, check the fanimpeller rotation direction and/or damper function.• Check that the hose or nozzle will not snag onany protruding parts on the vehicle.• Do not extract hot, burning or ignited materialor substances that might react with parts or materials from the suction system. • Risk of high temperatures! Use protection gloves or avoid contact with the hose or nozzleafter the system has been used. • FOR EMERGENCY APPLICATION: The system is designed for emergencyresponce only . Any other usage is strictly prohibited and could void the warranty of thesystem.

PRSPRS

44

GB

Mounting InstructionsGeneral ApplicationBefore PRS can be installed, a suitable position and height must be determined in relation to the vehicle's parking space in the parking bay.The distance from the floor to the bottom edge of the rail should normally be 3 - 5 m (10 - 16 ft). See figure 1 (1).The rail should be installed max 1.5 - 2 m (1 ft) from the side of the vehicle. See figure 2.The distance from the rail's leading edge to the exit door should be as small as possible, as long as the door can open freely without interference to the rail. The distance should however be at least 0,3 m (1 ft). See figure 1 (2).A PRS can be used with 1-4 suction trolleys per rail .

Emergency ApplicationBefore PRS can be installed, a suitable position and height must be determined in relation to the vehicle's parking space in the parking bay.The distance from the floor to the bottom edge of the rail should normally be 3 - 5 m (10 - 16 ft).The rail should be installed at least 0,3 m (1 ft)from the side of the garage opening. If the rail is to be used between two vehicles, the dis-tance between the vehicles must be at least 0,6 m (2 ft). See figure 3.The distance from the rail's leading edge to the station door should be as small as possible, as long the door can open freely without interference to the rail. The distance should however be at least 0,3 m (1 ft).A PRS can be used with 1-4 suction trolleys per rail .

AAB050

0,4 - 0,6 m (1.5 - 2 ft) min. 0,3 m (1 ft)

3 - 5

m (1

0 - 1

6 ft)

1

3

1

2

AAB053

1

AAB051

1,5 - 2 m (5 - 6,5 ft)2

IMPORTANT!For optimum function of extraction trolleys designed for moving vehicles, it is recommended that the vehicle does not drive further than 1.5–2.0 mparallel from the rail.

FlexFilter DXPRS

55

GB

The exhaust pipeThe edge of the exhaust pipe must have a freedistance to surrounding vehicle parts. See recommendations, picture 1.Check that the nozzle, after disconnection, does not catch any part of the vehicle. It is possible that modi-fications may be required to the exhaust system to ensure the optimum position of the exhaust pipe. Recommended diameter of 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. See figure 4.

≥ 4 in (100 mm)

≥ 4 in (100 mm)≥ 12 in (300 mm)

≥ 2 in (50 mm)≥ 2 in (50 mm)

≥ 4

in (1

00 m

m)

≥ 4

in (1

00 m

m)

≥ 2

in (5

0 m

m)

≥ 12 in (300 mm)

4

AAB070

PRSPRS

66

GB

EXIT

AAB058

5

EXIT

AAB060

6

Installation InstructionsMounting of railSee manual included in rail package. Leave room for putting in/taking out extraction trolley(s).Inserting trolley(s) in rail .See manual included in rail package.Ensure that the shock absorber is pointing in exitdirection.If necessary, move the pneumatic components on the trolley to the compressed-air feeding side of the extraction trolley.Mounting of several suction trolleys1–2 suction trolleys are normally fed from onesuspension wire and the compressed-air are fed from both front and rear. This is a standard performance. All trolleys have the same disconnection point. See figure 5.

3–4 trolleys require two suspension wires and pneu-matic feeding from both sides, front and rear. This is an alternative performance. For the first two trolleys it is possible to make a late disconnection. See figure 6.

FlexFilter DXPRS

77

GB

Mounting of suspension wire forcompressed-air hose spiral

Fit the two pipe brackets on the ends of the 1. exhaust rail. First of all hang two pipe brackets in the rail side and position them according to the measures in the picture. Carefully fasten the pipe brackets with supplied screws and rhombic nuts.Adjust the measure X, until the compressed-air 2. hose has plenty of room when the suction trolley is in its stop position. See figure 7.

Fit the wire with wire-lock in the pipe bend at the 3. rear rail end. See figure 8.

Hang up the compressed-air hose on the wire. 4. See figrue 9.

Fit the wire stretching device on the pipe bend at 5. the exit end of the rail. See figure 10.Cut off excessive part of the wire. Loosely wind up 6. the wire on the wire stretching device.

Angle the two pipes to suitabl7. e positions with regard to space. Horisontal is recommended. Fas-ten the pipe bends with the M6 screw. Then drill a hole 1/3 in (6.5 mm) dia. through the pipe bracket

9

AAB071

1-2 ft (300-600 mm)

≥ 2 in (50 mm)

X

A

AAB061

77

AAB063

8

AAB062

10

A

B

AAB064

11

PRSPRS

88

GB

AAB055

15

holes and the pipe and fasten the pipe with sup-plied M6 screws and nuts. See figure 11 (A, B).

Insert the compressed-air hose 8. spiral carrier into the trolley valve bracket. See figure 12 (B).Position the carrier in the suction trolley bracket, outside and close to the suspension wire, so that a centered compression of the compressed-air hose spiral is made. Tighten the screw. See figure 12 (A).Connect the compressed-air hose spiral to the 9. 3/2-valve.Fasten the compressed-air hose with stripes to the 10. carrier pin. Mount the disconnection trigger in the rail. Exact 11. position in the rail depends on exiting speed and number of trolleys etc. The exact position needs to be tested on site.Check the operation of the 3/2-valve. If necessary 12. the height position of the valve can be adjusted and the valve can be turned to reversed function.

Fit the filter regulator close to the pipe bend. 13. See figure 13.

N.B. The filter regulator must be fitted in a ver-tical position . The filter regulator is semi automat-ic (drains when feeding pressure is 0) and should have a draining hose connected at the bottom.

Compressed air connection14 . See the pneumatic diagram in figure 14. Blow the existing pneumatic hose system clean.Connect the compressed air, 87-116 psi (6–8 bar), to the filter regulator with a flexible hose to avoid-problems if the rail is moving.Connect the compressed-air hose spiral to the 15. filter regulator and adjust the pressure to 14,5 psi.

Adjustment of exhaust hose

Connect the nozzle kit on the1. safety coupling. See figure 15.

When applicable, fit the hose holder. Then fit the 2. balancer cord to the hose holder/metal elbow. See figure 16.

A

B

AAB069

12

AAB065

13

AAB 049

1 2 3

4

514

FlexFilter DXPRS

99

GB

3 . Metal elbowIt is important that the nozzle suspends freely (approx-imately 1 ft (30 cm)) from the floor 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 off the necessary length of the lower exhaust hose. d. Unscrew the hose clip for the compressed air hose.e. Cut the compressed air hose by the same length as the exhaust hose. Make sure the compressed air hose, after cutting, is 2 ft (0,6 m) longer than the 16 ft 5 in (5 m) exhaust hose.f. Reassemble the hose and the safety coupling.g. Check that there is no tension in the hose after the nozzle has been connected to the exhaust pipe.

3 . Hose holderIt is important that the nozzle suspends freely(approximately 1 ft (30 cm)) from the floor when the hose is in its raised position . The hose positioncan be adjusted by moving the hose slightly in the hose holder. For high mounting heights the hoseposition can be adjusted by moving the balancer cord stop the necessary length. 4 . Setting of the balancer lifting forceThe nozzle must not drag on the floor whendisconnected. Adjust it with the balancer.The balance block has a pre-set lifting force on delivery. Any adjustment of the lifting force should be done according to the following instructions.

Increasing the lifting forceLoosen the stop ball (C).1. Unscrew the safety knob (A).2. Use the supplied hex key or a ratchet handle (B), 3. twist anti-clockwise one turn at a time. A distinct

click is heard at the end of each turn. Continue turning until the hose is hanging in the desired resting position. Push the stop ball (C) up as far as possible. Screw 4. the stop ball into place in this position. Make sure the line protection sleeve is inside the stop ball and between the line and the stop screw.Twist the ratchet handle anti-clockwise one more 5. turn.Screw the safety knob (A) into place. 6.

Reducing the lifting forceUnscrew the safety knob (A).1. Use the supplied hex key or a ratchet handle (B)2. , turn slightly anti-clockwise. Then press the button (E). Allow to turn clockwise one turn at a time. With each turn, the button (E) will return to its original position.Screw the safety knob (A) into place.3. If necessary, adjust the stop ball’s position on the 4. line.

InspectionImportant! Make sure the safety knob (A) is firmly 1. fixed into place.The hose should return to its normal position 2. slowly. For this reason, pull the hose out com-pletely and check that the balancer lifts the hose back slowly. Hold onto the hose as it returns to its position.

AAB073

16

WARNING! Risk of personal injuries! Do not open the spring casette!

PRSPRS

1010

GB

Connection of exhaust extractionnozzle to exhaust pipeUse the manual switch to inflate/deflate the pneumatic nozzle. See figure 17 (1).

Connection of extra shock absorberWhen the exhaust extraction rail is 65.6 ft (20 m), or longer, the end stop shall be mounted and an extra shock absorber shall be mounted in the end stop. See figure 18.

Safety couplingThe system has a safety coupling which disconnects the hose if the nozzle has not been disconnected from the exhaust pipe when the vehicle is driven out of the premises. See figure 19 (2).The disconnection force is 500 N on delivery. Disconnection can be done manually by pulling the key ring on the hose just above the safety coupling.See figure 19 (1).

Locking systemExtraction unit 920/1500 with a balance block is delivered complete with a locking system that locks the hose in the chosen extended position. The lock is released if the hose is extended slightly further. In this case, the hose returns to its original position automati-cally. However, continue holding the hose until it reaches its resting position. The lock can be disen-gaged with a control switch (See figure 20):A . Engaged lock B . Disengaged lock

1

AAB066

17

1

2

AAB056

19

AAB067

A

B

20

18

AAB074

FlexFilter DXPRS

1111

GB

Fan connectionFans 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. See figure 21.To get underpressure in the ducting system and avoid exhaust leakage, the fan should be positioned as near the duct outlet from the facility as possible. Please con-tact your Nederman representative for advice on fan selection. A lockable safety switch is recommended for the whole electrical system including the fan.

AAB068

21

PRSPRS

1212

GB

Installation inspection/Service

Check the safety coupling function at least once 1. every two months. Check that it can be pulled apart with a force of approx. 500 N (= pulling strongly by hand. See figure 22.). Clean and lubricate the safety coupling as necessary. If the function does not work correctly, contact your Nederman dealer for technical advice.

Check the compressed air connection. Adjust the 2. pressure regulator so that the manometer shows 14.5 psi (1 bar).Check the filter regulator canister and empty when 3. necessary. Replace filter when necessary. Check the compressed air hose spiral for wear 4. also check for smooth travel along the wire.Operate the manual switch on the safety coupling 5. to check deflating/inflating of nozzle.Adjust the position of the disconnection trigger 6. on the rail to achieve the correct disconnection. Disconnection should be done at the door. Check that deflating/inflating of nozzle is done when the extraction trolley passes back and forth over the disconnection trigger.Check that the hose returns correctly after 7. disconnection. See previous section Setting of the balancer lifting force.

Check the airflow in the nozzle opening using 8. an airflow meter. If necessary, check the rotation direction of the fan impeller and/or the damper function.Check that the hose and the nozzle cannot catch 9. in any part of the vehicle or any other item.Check the bolted joint on the suspension device.10. Check the screw joint on the rail profiles.11. Check the rail’s end stop and trolley stop.12. Check the balancer line.13. Check the shock absorber(s).14. Check that the extraction trolley slides easily along 15. the entire length of the rail. Check the wheels of the extraction trolley.Check the extraction trolley’s slide surfaces for 16. wear (against the sealing strips). Clean the slide surfaces if necessary.

Spare PartsSee www.nederman.com When ordering spare parts always state: • Part no. and control no. (see type label of the product). • Name of the spare part. • Quantity of the parts required.

AAB054

22

WARNING! Risk of personal injury!Always turn off the power supply and the compressed air connections to the system before performing service.

Regular maintenance is required to maintain a high level of operational reliability in the system . Check and correct points 1–9 immedi-ately after installation . Check and correct all the points at least twice a year, as necessary, or when spare parts are changed .

PRS

Nederman is represented in:Australia, Austria, Bahrain, Belgium, Brazil, Bulgaria, Canada, China, the Czech Republic, Cyprus, Denmark, Egypt, Estonia, Finland, France, Germany, Greece, Hong Kong, Hungary, Iceland, India, Iran, Ireland, Italy, Japan, Korea, Latvia, Lithuania, Malaysia, the Netherlands, Norway, Philippines, Poland, Portugal, Romania, Russia, Saudi Arabia, Serbia & Montenegro, Singapore, Slovenia, South Africa, Spain, Sweden, Switzerland, Taiwan R.O.C., Thailand, Turkey, United Arab Emirates, United Kingdom, USA.

www .nederman .com