Nederman 920/1500 Installation And Service Manual Download Page 4

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Trolley Return Unit 920/1500

English

Installation and service manual

Exhaust Extraction

Trolley Return Unit 920/1500

1 Declaration of conformity

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2 Preface

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3 Notices

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4 Description

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4.1 Components

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4.2 Technical information

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5 Installation

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5.1 Assembly instructions Trolley Return Unit 920/1500

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5.2 Description of cable and end marking

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5.3 Installation of cables and connection boxes

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5.4 Electrical continuous test (2 persons required)

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5.4.1 Check cable W1

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5.4.2 Wiring tests

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5.5 Installation checking

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6 Work procedure (Normal operation)

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7 Malfunction (Drive unit motor moves the suction trolley)

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8 Spare parts

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9 Troubleshooting

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Appendix A: Cable connections ................................................28

Cable connections overview .....................................................................28

Simple cable connections overview ..........................................................29

Appendix B: Circuit diagrams ...................................................30

Driving slot circuit diagram .......................................................................30

Circuit diagram 1 ......................................................................................31

Circuit diagram 2 .......................................................................................32

Circuit diagram 3 .......................................................................................33

Circuit diagram 4 .......................................................................................34

Circuit diagram 5 .......................................................................................35

Circuit diagram 6 .......................................................................................36

Circuit diagram 7 .......................................................................................37

Circuit diagram 8 .......................................................................................38

Circuit diagram 9 .......................................................................................39

Circuit diagram 10 .....................................................................................40

Table of contents

Summary of Contents for 920/1500

Page 1: ...Installation and service manual Exhaust Extraction Trolley Return Unit 920 1500 144259 02 Original installation and service manual INSTALLATION AND SERVICE MANUAL EN ...

Page 2: ...Trolley Return Unit 920 1500 2 ...

Page 3: ...Trolley Return Unit 920 1500 3 English 4 ...

Page 4: ...us test 2 persons required 20 5 4 1 Check cable W1 20 5 4 2 Wiring tests 21 5 5 Installation checking 24 6 Work procedure Normal operation 25 7 Malfunction Drive unit motor moves the suction trolley 25 8 Spare parts 26 9 Troubleshooting 27 Appendix A Cable connections 28 Cable connections overview 28 Simple cable connections overview 29 Appendix B Circuit diagrams 30 Driving slot circuit diagram 3...

Page 5: ...nstallation repair and maintenance work for this product is to be carried out by qualified personnel using only original spare parts Contact the nearest authorized distributor or Nederman for advice on technical service and obtaining spare parts Nederman continuously improves its products design and efficiency through modifications and reserves the right to do so without introducing these improvem...

Page 6: ...ion trolley passes activating speed reduction SL4 Limit switch Detects when the stop ball passes disengaging the drive motor C_BOX_1 Connection box Vehicle exit end C_BOX_2 Connection box Vehicle entrance end C_BOX_3 Connection box Accessory location in the centre of the extraction rail same as C_BOX_2 CR_BOX_1 2 button control box Emergency stop and Start button Figure 1 Component overview Drive ...

Page 7: ... galvanic separation of Fan Starters F Fuse 10 A time lag T Fuse in control board 10 A time lag T fusing the drive motor F1 Fuse 2 A time lag T Fuse in terminal block X1 2 or 4 A time lag T depending on transformer voltage setting according to Circuit diagram 1 power supply fusing of 24 V transformer F2 Fuse 2 A time lag T Fuse in terminal block X2 2 A time lag T 24 VAC fusing of 24 VAC supply to ...

Page 8: ... 1500 First of all decide if the Trolley Return Unit is to be installed on the Left Hand side LH or the Right Hand side RH of the 920 rail as seen from the vehicle s travel direction see Figure 2 Consideration must be taken to available space and which other system with special needs shall be fitted to the rail For example a Magna Rail System shall be installed on the same side as the vehicle is s...

Page 9: ...ove the suction trolley stop from the rail see Figure 3 a Drill holes for the motor unit brackets as illustrated RH Drill holes on other side of suction trolley stop b Fit and secure the Drive unit brackets on the suction trolley stop RH Fit the supplied rubber stop extension according to Figure 3 2 Fit and secure connection box 1 on the other side of the suction trolley stop see Figure 4 Use the ...

Page 10: ...lot on the suction trolley see Figure 8 item a RH Disassemble the driving slot first and reassemble it according to Figure 8 item b NOTE The supplied spacer washer must be used between suction trolley and angle bracket Caution Risk of equipment damage If the overload release screw is adjusted to contact with steel springs it will cause the system to malfunction due to a limit switch signal short c...

Page 11: ...alance block wire and ensure that the catch is locked see Figure 10 item a 13 Loosen the balance block wire from the exhaust hose mounting 14 Remove the existing control ball spring and wire stop from the balance block wire Thread the balance block wire through the limit switch SLX ring and through the supplied plastic limit switch actuator with spring and through the wire stop in accordance with ...

Page 12: ...g force must be adjusted so that the spring is compressed to 50 of its original length L see the instruction manual 144226 Exhaust Rail System 920 1500 19 Disengage the balance block catch See Figure 10 20 Position the suction trolley in the intended connection position i e exhaust hose connection to vehicle 21 Remove the rail connection sleeve See Figure 16 22 Fit the end stop A to the suction tr...

Page 13: ...rk on the suction trolley so that the spring fork is then roughly in the centre of the arrow see Figure 14 If necessary adjust the position of the arrow laterally so that it is in the centre of the spring fork Fix the disconnection arrow to the rail in this position 25 Fit the inductive sensor SL2 approximately 0 7 m in front of the disconnection arrow see Figure 15 The position can be adjusted if...

Page 14: ...e wire through the driving slot on the suction trolley see Figure 8 item a d Thread the upper wire around the drive unit drive pulley and idler pulleys see Figure 17 and Figure 19 e Hang the upper wire over the guide pulley see Figure 7 Pull and tighten the wire so that it becomes adapted to the length of the rail f Make sure both loose ends of the wire are of equal length so that the connecting k...

Page 15: ...Check that the wire is running in the centre of the driving slot spring fork on the suction trolley Adjustments can be made by laterally pressing the idler pulley unit panel slightly See Figure 19 31 Mount the supplied stop balls on the wire directly before each knot with regard to wire travel direction See Figure 20 item a NOTE The hexagon socket screw must be tightened against the wire protectio...

Page 16: ...carbon brushes are then in the correct position laterally against the bus bar Then tighten the screws A see Figure 22 item a 35 Determine a suitable location for the control boxes 36 Fit the control box start stop on the wall close to the vehicle departure rail end see circuit diagrams 2 to 4 Assembly height from the floor is approximately 1 4 meters 37 Fit the control box start stop manual auto o...

Page 17: ...dentification See Appendix A Cable connections overview The wires in the cables W1 and W2 are marked with numbers The wires in the cables W3 to W8 are marked with colours Tools and materials Stripping pliers insulation on the wires must be stripped by 10 mm to ensure good contact in the terminal blocks Cable cutters knife drill machine automatic screwdriver Instrument screwdriver maximum 4 mm wide...

Page 18: ... of electric shock The power supply must be disconnected from the drive unit If the power supply cable is already installed to the drive unit then the power supply must be disconnected from the drive unit Switch off the working switch and lock the knob with a padlock and mark this with the sign Work in progress Cable W2 1 Route the cable W2 into connection box 1 2 Route the cable to the left in th...

Page 19: ...x 2 and connect in accordance with Appendix B Circuit diagram 2 2 Route the cable over the extraction channel maintain the cable s length 3 m press the red female pin sockets onto the wires and connect to SLX1 disconnection arrow s rear edge 3 Affix the cable with fasteners and cable ties Cable W6 1 Route the cable W6 embedded cable from limit position SL2 Inductive sensor 2 Route the cable over t...

Page 20: ...ntinuous test Cables W13 to W15 with the associated power components constitute a power current installation Power components are fan working switches and starting devices for the fan A qualified electrician must perform the installation and the connection to the network Green marked components and pink marked cables are included in the suction trolley return and are installed by Nederman s electr...

Page 21: ...he Disconnection Arrow 2 Set Control Box 2 AUTO MAN switch in manual mode 3 Place the black test probe in terminal 6 4 Place the red test probe in terminal 3 5 Press all start buttons one at a time If the wiring is installed according to the schematics the buzzer sounds when you press the buttons 2 Test the Automatic Manual switch 1 Place the black test probe in terminal 3 2 Place the red test pro...

Page 22: ...t Switch actuated 5 Place the black test probe at one of the Driving Slot springs 6 Place the red test probe at the other Driving Slot springs 7 Pull the exhaust hose up and down so the Limit Switch on the trolley SLX is trigged on and off If the wiring is installed according to the schematics the buzzer sounds when the hose is in raised position Limit Switch actuated If the buzzer sounds while th...

Page 23: ... Buttons one at a time by push and pull After each test make sure the button is pulled out reset When one or several Emergency Stop Button s is activated pushed in the buzzer does not sound 10 Test the Inductive Sensor SL2 1 Place the black test probe in terminal 6 2 Place the red test probe in terminal 2 If the wiring is installed according to the schematics the buzzer sounds when the Driving Slo...

Page 24: ...disconnection arrow Check that the motor damper closes or the fan stops When the carbon brushes are inside the bus bar and the hose is in raised position activated Limit switch When the start button on the Control box has been activated trolley return activated Check the wire tension as follows See point 28 Too high wire tension Check the return time for the suction trolley s return For 35 m rail ...

Page 25: ...he drive motor s speed is reduced the suction trolley is parked in SLX1 connection position with reduced speed Reduction of the drive motor s speed before connection position minimises back swing of the exhaust hoses when the suction trolley is parked in connection position Disconnection arrow SLX1 opens the Driving slot springs on the driving slot which releases the suction trolley from the stop ...

Page 26: ... ball If the hose suction trolley jams for some reason then the driving slot will disengage from the stop ball and the suction trolley return is interrupted The drive motor will continue to run until the stop ball reaches the limit position SL4 when the motor is stopped When you have rectified the problem that caused the disconnection you can restart the drive motor with a start button The driving...

Page 27: ...rd in the Drive unit Check the emergency stop Contact K1 is off when the emergency stop is depressed Measure the voltage on K1 to the drive motor 15 24 VDC The Drive motor starts but stops after 3 seconds Check limit switch SL4 release SL4 from the stop ball and measure on the wires when SL4 is unaccuated If SL4 is closed when unaccuated SL4 is open when unaccuated and closed when accuated then se...

Page 28: ...Trolley Return Unit 920 1500 EN 28 Appendix A Cable connections Cable connections overview ...

Page 29: ...Trolley Return Unit 920 1500 29 EN Simple cable connections overview ...

Page 30: ...Trolley Return Unit 920 1500 EN 30 Appendix B Circuit diagrams Driving slot circuit diagram ...

Page 31: ...Trolley Return Unit 920 1500 31 EN Circuit diagram 1 ...

Page 32: ...Trolley Return Unit 920 1500 EN 32 Circuit diagram 2 ...

Page 33: ...Trolley Return Unit 920 1500 33 EN Circuit diagram 3 ...

Page 34: ...Trolley Return Unit 920 1500 EN 34 Circuit diagram 4 ...

Page 35: ...Trolley Return Unit 920 1500 35 EN Circuit diagram 5 ...

Page 36: ...Trolley Return Unit 920 1500 EN 36 Circuit diagram 6 ...

Page 37: ...Trolley Return Unit 920 1500 37 EN Circuit diagram 7 ...

Page 38: ...Trolley Return Unit 920 1500 EN 38 Circuit diagram 8 ...

Page 39: ...Trolley Return Unit 920 1500 39 EN Circuit diagram 9 ...

Page 40: ...Trolley Return Unit 920 1500 EN 40 Circuit diagram 10 ...

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