Vertical Stack Rail System
Contents
1. N JL VSR Catcher P including gate damper E v1 Prod VSR CAT VSR Kit consisting of suspension profile 2 suspension brackets and trolleys centering spring safety wire trolley stops and hard ware for one suspension point Prod VSR SUS PUM VSR 100209 EN 6 20 7 MOUNTING INSTRUCTION Measure the mounting height WARNING PRODUCT MAY CONTAIN SHARP EDGES Use care when servicing unit Failure to do so could result in minor personal injury The height of the rail is determined by measuring the distance between the floor and the end of the vehicle exhaust pipe The measure between the top of the exhaust pipe and the horizontel suspension VSR SUS is 445mm 17 5 600mm 23 62 Min 445mm l 7 5 375mm 300mm 1 1 8 Suspension This is the standard support for VSR included in all models PUM_VSR_100209_EN 7 20 7 MOUNTING INSTRUCTION VSR rail 2 Catcher 3 Support brackets 4 Horizontal support 5 Vertical support Put the VSR parts under the rails intended position The catcher must be positioned as close as possible to the gate with a safety distance of 50 100 mm 2 4 Check and determine the location of the support legs accord ing to the required distances between support legs and the catcher as shown below The vertical support pipe 5 is to be slid onto the horizontal support profile 4 Level the support WARNING PRODUCT MAY CONTAIN SHAR2. Drill a 8 5 mm 0 33 hole 100 mm 4 from the support leg as shown in the picture below Screw the safety eyebolts to the rail with 2 pcs of M8x25 Mount the safety wires with a wirelock into the safety eyebolts and around the support pipe as shown below or around the ceiling beams PUM VSR 100209 EN 13 20 7 MOUNTING INSTRUCTION HOSE CONNECTION VSR profile 2 Hose connection d 160 mm 6 3 L 1 3 m 4 2 3 Connection socket d 160 mm 6 3 Mount the hose between the connection socket and the duct connection The length of the hose must be adjusted so that it reaches the outer side positions of the rail VSR systems longer than 18 m 59 should have several connection sockets at the top of the rail These must be positioned at an equal distance from one another Cut a hole with a diam of 160 mm 6 3 and fasten the socket with self rivet screws Connect the hoses in the same way as the end connection il SN M ENS EZ 27 ph we IIT i PUM VSR 100209 EN 14 20 7 MOUNTING INSTRUCTION STACK ADAPTER Stack adapter 2 Exhaust pipe The exhaust pipe must be straight vertical and cut in a 90 angle to fit the stack adapter Mount the stack adapter onto the exhaust pipe and fasten it by tightening the lock bolts Note The distance between the exhaust pipe and the horizontal support leg must be a minimum of 445 mm 7 5 For further informati
3. is the required length of the rail The VSR is normally positioned immediately after the gate at a distance of approx 50 100 mm 2 4 Check the height of the exhaust pipe see further under measurement procedures see next page for required space for exhaust pipe The distance C C exhaust pipe and truck body 5 is the required rail position from the truck body PUM VSR 100209 EN 10 20 7 MOUNTING INSTRUCTION SUPPORT BRACKETS WARNING PRODUCT MAY CONTAIN SHARP EDGES VSR profile i Use care when servicing unit 2 Support bracket Failure to do so could result in minor personal injury The support brackets are to be positioned according to the support measurement procedure It is important that they are 1 mounted exactly at the support leg position Drill 8 5 mm 0 33 holes and bolt together every support bracket with 2 pcs of M8x25 with nuts RAIL SPLICE VSR profile 2 Splicing sleeve Put the rail parts under its intended position on trestles or similar Align the profiles vertically and horizontally Fix the splicing sleeve with a clamp drill according to the drawing below with a 8 5 mm 0 33 drill bit and screw the splicing sleeve to one of the profiles Put on the other profile position the splicing sleeve horizontally and vertically drill and screw together Every splicing sleeve is to be bolted together with 12 pcs M8x25 PUM_VSR_100209_EN 11 20 7 MOUNTING INSTRUCTIO
4. of rubber seal Unscrew the catcher A from the VSR profile B Pull of the old rubber seal Before mounting the new rubber seal they must be greased with liquid soap Mount back the catcher A on the VSR profile Trolley change Start by dismounting the spring D Unscrew the stopbolt E on the horizontal support C profile Pull carefully the rail to the side until the support trolley F appears Note Be careful when pulling the rail to the side to avoid both support trolleys to slide out of the hori zontal support leg Unhook the safety hook G from the support trolley and change the support trolley to a new one Hook the safety hook onto the new support trolley and push the rail back in the normal position Refit the stopbolt E and the spring D Check that the rail moves smoothly in the support Change of rubber gate H Unscrew the old rubber gate H Mount the new rubber gate in the same position PUM_VSR_100209_EN 18 20 SPARE PARTS 9 SPARE PARTS BSAB No T3 1 pP LY M rj V Rd T SPARE PARTS LIST ser No VSR RR Date Aug 98 Replace Copyright All right reserved All information within this printed matter may not be VSR RAILS reproduced handed over copied xeroxed or translated into another language in any z form or any means without written permission from PlymoVent AB PlymoVent AB reserves the right to make design changes Produkt No
5. A All models lt 1 lt lt Qoo 2 2 2 12 VSR 12 D VSR 15 VSR 15 D VSR 18 VSR 18 D VSR 21 VSR 21 D L MSR24 o eT D Abreviations X Order as requiered state requiered length c 2o 0 3 S a z lt o AJ Y Depending on ceiling hight Pos Art No A B A Description Note 1 820 DS 11 1 1 2 1 2 1 2 1 2 1 2 Catcher o 3 902 DM 1 1 1 211 2 1 2 1 2 1 2 Rubber Gate 4 1149 1416 6 6 6 6 8 8 8 8 10 10 Support bracket __ _4_ 1962530 1 41 61 61 61 6 6 8 8 8 8110 10 Safety Hook 5 4138__ 41 61 61 6 6 6 8 8 8 8 10 10 Support Trolley 6 516187 2 31 31313 3 4 4 4 4 5 5 Horizontal SBT profile L 1 2m 7 8120 1011 X j P prp 8 18150 1011 _ 4 6 61 6 6 6 8 8 8 8 10 10 Mounting Kit Vertical 9 8145 1011 Y P Side Brace Kit Short 9 8146 1011 Side Brace Ki Medium 9 18147 1011 ISide Brace Kit Long 10 964155 2 3 3 3 3 3 4 4 4 4 5 5 Safety wire 11 968180 X 21313131313 4 4 4 415 5 Centering Spring _12 3005__ Rubber Seal When ordering spare parts please quote CD E O m Product No see label Batch No Description Part No Quantity For example VSR S upport Trolley 4 1378 MHR Eng 2 PUM VSR 100209 EN 20 20
6. N MOUNTING OF RUBBER SEAL WARNING PRODUCT MAY CONTAIN SHARP EDGES Use care when servicing unit Failure to do so could result in minor personal VSR profile injury 2 Rubber seal 3 Tool no 11600 4 Tool no 11606 Turn the rail profile with the opening upwards If the seal must be joined it must be done before mounting The rubber seal should overlap and be cut together with a sharp knife The rubber seal ends are to be fixed together with glue Loctite no 495 or similar rubber glue Note The rubber seal is to be greased with liquid soap before mounting The rubber seal is mounted with tool no 11600 The rubber seal is easily mounted with tool no 1606 the rail profile hanging in its support legs Note The rubber seal must be angle inward PUM_VSR_100209_EN 12 20 7 MOUNTING INSTRUCTION LIFTING THE RAIL VSR profile 2 Support bracket 3 Horizontal support C profile 4 Support trolley with safety hook Lift the rail with a minimum of lifting points every 10 m 33 Attach the safety hook of the support trolley to the support brackets according to the picture below C C SPRINGS SAFET Y WIRES VSR profile 2 Centering spring 3 Safety wires Drill a 6 5 mm 0 25 hole 800 mm 2 6 from the support leg as shown in the picture below Screw the M6 eyebolts with M6 nuts into the hole Fix the centering spring between the hook on the horizontal support and the eyebolt
7. P EDGES Use care when servicing unit Failure to do so could result in minor personal injury PUM_VSR_100209_EN 8 20 7 MOUNTING INSTRUCTION CATCHER AND CONNECTION SOCKET WARNING PRODUCT MAY CONTAIN SHARP EDGES Use care when servicing unit Failure to do so could result in minor personal VSR rail injury 2 Catcher 3 Connection socket 4 160 mm 6 3 Mount the catcher at the exit end of the rail Drill 8 5 mm holes in the profile according to the hole structure on the catcher The catcher is to be mounted with 2 pcs M8x25 and 2 pcs M8x45 with nuts Mount the connection socket d 160 mm 6 3 to the opposite end of the rail with 4 pcs M8x20 PUM VSR 100209 EN 9 20 7 MOUNTING INSTRUCTION MEASUREMENT PROCEDURES WARNING PRODUCT MAY CONTAIN SHARP EDGES Use care when servicing unit Failure to do so could result in minor personal Exhaust pipe injury Stack adapter Exhaust pipe height Distance between gate and exhaust pipe Distance C C exhaust pipe and vehicle body Ui Back In Measure the distance between the gate and the exhaust pipe This distance 4 plus m minimum is the required length of the rail Note The vehicle must be as far away from the gate as possible in back in position Drive Through Measure the distance between the exit and entrance gate This distance minus 0 5 1 0 m 1 6 3 3 depending on free space from gate
8. PLYMFVENT clean air at work PRODUCT USER MANUAL contents Important safety instruction 2 2 Introduction eee eececesesseceececeesecescecesseceeseceessceessceessceeeees 2 3 Product description esses 2 OY cS ANC EY 3 Se ucc ro MU E 4 NIU 4 6 7 Mounting instructions eese 7 16 Measure the mounting height sues 7 8 Catcher and connection 9 Measurement 10 Support bracket and spliceing the profile E Mounting rubber 12 Lifting the rall 13 erii m 3 Hose 14 Stack adaptor 15 Pc 500 mounting procedure l6 8 Maintenance uu eeeesscecsececeececesceeesceeceseceessesecseees 17 18 9 Spare 19 20 Thank you for buying a Plymovent product Before you unpack and put it into operation please read this product manual carefully and follow the instructions This manual should be handed over and kept by the service department after the installation Sales office England Canada USA Plymovent AB Plymoven
9. TTENTION with vertical top exhaust pipes The system can be applied to The VSR System is designed to operate under stan single or multiple lines of vehicles per bay and also for drive through systems dard vehicle performance conditions Re generation is not considered to be a standard vehicle perfor mance condition Method of Operation An automatic mechanical exhaust gas extraction system specially designed for fire and rescue vehicles with top exhaust pipes The system is used to remove the poisonous petrol and diesel gas fumes direct at the emission source the exhaust pipe When the vehicles reverse or drive in to the fire station a catcher box picks up on the special tapered connection on the vertical exhaust pipe aligning itself on the aluminium pro file both upwards and sidewards As the vehicles continue into the station the exhaust pipe gli des along the rubber sealed profile until the vehicle is parked All of the poisonous exhaust gases being contained in the profile under vacuum to be extracted by a fan to the outside of the building Upon a call out the vehicles glide out of the profile in a similar way and the track resumes it s natural position by the use of mounting springs Safety wire Side view Front view Support leg Stack adapt Centering spring ack adapter Catcher 1 Aluminium Rail SL m Overview PUM VSR 100209 EN 4 20 6 DELIVERY T
10. h 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 WARNING Denotes risk of electric shock WARNING A Important warning to prevent fire Service and technical support For information about specific adjustments maintenance or repair jobs which are not dealt with in this manual please contact the supplier of the product He she will always be willing to help you Make sure you have the following specifications at hand The VSR Product User Manual PUM_VSR_100209_EN l l Identification of the product The VSR system is made up out of various different parts which together form the VSR Exhaust Removal System All these individual parts can be traced back to this Product User manual 3 PRODUCT DESCRIPTION The VSR System consist of a strong rectangular aluminium profile with a section area of 280 cm2 The underside of the rail is an open area sealed with rubber lips The profile is hung in two 2 bearing loaded trolleys at each support The profile is connected to the ducts system by a 160mm 6 3 flexible hose The front opening of the profile has a V formed catcher to accommodate t
11. he VSR in all different versions is built out of a few standard components which will be described in this section Support leg The aluminium support leg is used for both vertical and horizontal mounting The standard length is 19 5790 mm and it has to be cut to proper lengths The dimension is 2 x 2 x 0 1 50x50x2 5 mm Side brace There are three different lengths available 20 500 mm 30 750 mm and 6 1800 mm The brace can be mounted separately or in pairs using the same brackets Side brace clamp kit The kit includes two aluminium brackets for one or two side braces Adjustable mounting kit vertical The two brackets are exactly the same They can also be used if the roof is angled and they can be mounted in both directions Maximum angle is 30 degrees VSR Extraction rail The VSR track is 5 8m I9ft or ordered by meter PUM VSR 100209 EN Prod SBT SL Prod SBT SB S 20 500mm Prod SBT SB M 30 750mm Prod SBT SB L 6 1800mm Prod VSR Track 5 20 6 DELIVERY The VSR in all different versions is built out of a few standard components which will be described in this section Drive through Connection Se A gt with top connection flexible hose 3 1 m 10 2 ft and hose W A clamps D FA Ze A RS 2 Gy Prod VSR DTC Back In Connection with end connection flexible hose 1 3 m 4 3 ft and hose clamps C F Prod VSR BIC
12. he stack adapter mounted on the vertical exhaust pipe The exhaust cone converts the round shape of the exhaust pipe to be flat without changing the section area As the returning fire engine drives in to the station the catcher and the profile align themselves to the exhaust pipe position This movement is created via the bearing loaded runners sliding in the C profile of the support leg The C profile hangs in two adjustable vertical legs mounted to the general roof structure The support legs allow the VSR to have a lateral movement from two separate points of 2 feet side to side As the fire engine drives out of the station the exhaust pipe glides along the profile between the rubber lips up to the point the vehicle drives out of the station A spring is connected between the support legs C profile and aluminium profile to move the rail into its central rest posi tion The VSR System is equipped with safety wires capable of carrying the complete system As the vehicles continue into the station the exhaust pipe gli des along the rubber sealed profile until the vehicle is parked All of the poisonous exhaust gases being contained in the profile under vacuum to be extracted by a fan to the outside of the building Upon a call out the vehicles glide out of the profile in a similar way and the track resumes it s natural position by the use of mounting springs 2 20 4 SAFETY General The manufacturer does not acce
13. ned and qualified users Temporary personnel and personnel in training can only use the product under supervision Intended use The product has been designed as an exhaust removal system Using the product for other purposes 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 specifications The specifications given in this manual must not be altered Modifications Modifications of parts of the system product is not allowed PUM VSR 100209 EN WARNING Do not attempt installation of this system unless you are familiar with the necessary tools equipment utility connections and potential hazards Installation should be performed only by a qualified service provider Failure to do so could result in reduced performance of the unit serious personal injury or death WARNING PRODUCT MAY CONTAIN SHARP EDGES Use care when servicing and installing the system Failure to do so could result in minor personal injury General information and installation Inspect the product and check for damages Verify the functioning of the safety features Check the working environment Do not allo
14. on see support legs measurement Final adjustment of the VSR rail and the stack adapter height is to be done when the vehicle drives into the appliance bay PUM_VSR_100209_EN 15 20 7 MOUNTING INSTRUCTION PC 500 MOUNTING PROCEDURE VSR profile 2 PC 500 Pressure controller 3 Drilling machine with 10 mm 0 4 drillbit Drill a 10 mm 0 4 hole in the VSR profile nearby the crab when the vehicle is in its rest position Thread the pressure controller directly into the VSR profile Mount a pressure controller the same way at the end of the exit side on the rail to achieve fan start when the vehicle returns Connect the electrical low voltage cables to the pressure controller with accompanying tags Further connection to pressure control unit PCU 1000 see separate electrical diagram ELEVATION VIEW 360mm PUM VSR 100209 EN l60mm 6 3 16 20 MAINTENANCE INSTRUCTION Routine check and maintenance shall be performed according to the following sche dule 0 500 call outs year 500 1500 call outs year 1500 3000 call outs year 3000 call outs year every 16 weeks every 12 weeks every 8 weeks every 4 weeks 1 Clean the inside of the rubber seals 2 Check that the rail runs smoothly in the horizontal support 3 Check for mechanical damages on support legs trolleys and safety hooks PUM_VSR_100209_EN 17 20 MAINTENANCE INSTRUCTION Change
15. pt 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 Specific 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 Please 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 herein 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 or near 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 Theuse of this product is exclusively reserved to authorized trai
16. t Ltd Plymovent Inc Plymovent Corp Kopparbergsgatan 2 Marley Way Southam Road 24 1200 Aerowood Dr 115 Melrich Road SE 214 44 MALMO Banbury OX16 2RA England Mississauga On L4W 2S7 Canada Cranbury New Jersey 08512 USA SWEDEN Tel 44 1295 25 93 11 Tel 1 905 564 4748 Tel 609 395 3500 Tel 46 40 30 31 30 Fax 44 1295 27 17 50 Fax 1 905 564 4609 Fax 609 655 0919 Fax 46 40 30 31 40 info plymovent ca info plymovent ca info plymovent com PUM VSR 100209 EN Rev I I Plymovent AB reserves the right to make design changes IMPORTANT SAFETY INSTRUCTIONS 2 INTRODUCTION Please read these instructions before installing the Vertical Stack Rail System hereafter called VSR This will help you obtain the full benefit from the exhaust removal system you have selected A Read the Product user manual and Safety Instructions carefully Failure to follow these instructions could cause a malfunction in the system or unsatisfactory performance B Follow a regular service and maintenance schedule for efficient operation PREFACE Using this manual This manual is intended to be used as a work of reference for professional well trained and authorized persons user s 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 wit
17. w unauthori zed 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 influence of drugs alcohol or medicine Make sure the room is always sufficiently ventilated this applies especially to confined spaces make sure the product does not block any entrances and exits which must be used for emergency services Make sure that the workshop in the vicinity of the product contains sufficient approved fire extinguishers if any elctronics such as control boxes are used Service maintenance and repairs Observe 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 tools materials lubricants and service techni ques which have been approved by the manufacturer Never use worn tools and do not leave any tools in or on the product Safety features which have been removed for service maintenance or repairs must be put back immediately after finishing these jobs and it must be checked that they still function properly ATTENTION Maintenance should only be performed by autho rized qualified and trained persons skilled using appropriate work practices 3 20 5 Area of use The VSR system is used in fire and rescue stations on vehicles A
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