DuctSox U-Track Installation Manual

Page 1

Installation Guide

U-Track

Thank you for selecting a DuctSox System. This guide will be helpful for the installation of a U-Track System. Sections of fabric will be labeled, assembled, bagged, and boxed for shipping. More complicated systems will include a CAD detail of the system identifying what is in each package.

Overview

Inventory

The rst step on any installation project is to read through this guide thoroughly and review the components that need to be installed. The best way to do this is to review the drawings of the project

while reading the guide, including the CAD detail if applicable.

Shipping/Receiving

In some cases the DuctSox support system is delivered to the job site ahead of the DuctSox fabric sections. Depending on the size of a project or order, a DuctSox system will be shipped by common courier in a single brown box or several boxes. Larger orders will be shipped in crates by a common freight courier. Each DuctSox length should be packaged into individual plastic bags and labeled

according to size and number of pieces. Other markings or labeling may also be incorporated for

larger or more complicated systems. Be sure you have determined all boxes are accounted for.

Unpacking

Inspect shipment carefully and make sure all pieces are accounted for. Account for everything by

emptying the box and examining all contents. Note any missing or damaged pieces listed on the Bill of

Lading.

Labeling

Each DuctSox section will be marked with the size and section number either inside the belt of the inlet or on a tag inside the DuctSox near the zipper. The marking shall be the diameter, section length

and total length. If custom labeling has been used, locate an identication sheet that will be included with the delivery.

Equipment Required:

• Drill/driver and magnetic #2 Phillips driver bit

• Level

• #2 Phillips screwdriver

• Tape measure

• Marker or pencil

• Wrenches for cable-to-track connection (7/16” and 7/32” or pliers)

• Flat (standard) screwdriver

• Cable cutter

Installation Guide:

U-Track

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Component Details

Optional:

Cord-In Attachment may be used as an

alternative to Gliders

Glider Attachment

Hook of Cable Support

Track Stop

Quick-Connection and

Stud Cable End

Cable Clamp for

U-Bolt option

U-Track

Coupler

Alternate clamp for

Pool applications

Aluminum

U-Track

U-Track Endcap

U-Bolt for

U-Bolt option

Installation Guide:

U-Track

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Installation Steps

1. Review materials in box, including the CAD drawing and installed location of the DuctSox

2. Prepare metal inlet collar for fabric connection

3. Mark placement of track. (1 Row, 2 Row, and 3 Row Style) Install track (with couplers and track supports OR surface mount clips)

4. Install and assemble DuctSox components

5. Start up AHU

6. Balance airow

Step 1

Review materials in box, including the CAD drawing and installed location of the DuctSox. READ

INSTRUCTIONS THOROUGHLY BEFORE BEGINNING.

Step 2

Prepare metal inlet collar for fabric connection.

• Conrm inlet air supply location.

• Conrm inlet air supply size.

• DuctSox inlets are manufactured 1/2” (12mm) larger than

specied to t over metal inlet collar.

• Metal collar length should be 6”–10” (150 to 250cm) for

secure fabric attachment.

• Edge Guard (provided) should be installed on the edge of

the metal collar to reduce fabric wear from the metal edge.

6”–10”

(150 – 250cm)

Edge Guard

(Supplied)

Step 3

Mark Placement of Track. Step 3 is broken into three types of suspension points: 1 Row, 2 Row, and 3

Row. One job may use multiple styles.

Step 3 – 1 Row Style Step 3 – 2 Row Style Step 3 – 3 Row Style 10 and 2 O’clock 10, 2, and 12 O’clock

Installation Guide:

U-Track

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The following three details (Track and Internal Couplers, Track Supports, and End Caps) are used for ALL styles.

Track and Internal Coupler

Track sections are shipped in 8 ft (2440mm) standard

lengths.

Coupler assembly consists of a 12” (305mm) long coupler

and 4 self-drilling screws as pictured.

Coupler is inserted into one track about 6” (150mm) and secured with two screws. Screws are driven through the top

of the track to secure coupler and track in place. Note: Use screws supplied.

Insert the rest of the coupler into the other track. Be sure to get each section of track as close together as

possible so that the coupler is not visible. Secure the coupler in the tracks with two screws for each track.

Installation Guide:

U-Track

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Track supports: Quick-connection or U-Bolt

The Track Supports are the main structural support between the U-track & DuctSox and the structure of

the building. A Quick-Connection Track Support OR a U-Bolt Track Support are the available options.

Standard

Pools

Quick-Connection Track Support Option U-Bolt Track Support Option OR Pool Applications

Hook end is attached

to structure above the

DuctSox. DO NOT loop the hook back onto the cable, this could cause the hook to detach. Hook must be hooked into part of the building structure, for example an eyebolt attached to the ceiling. Nut on the end of the stud is

permanently xed and is not adjustable. This nut is

slid into the top channel of the track. After stud and cable are in their proper location the top nut

(7/16”wrench) on the stud must be tightened onto

the track while holding the stud with a pliers. After

adjusting the track height trim excess cable as

needed.

A roll of cable, U-bolts, square nuts for U-bolts, regular nuts for U-bolts and cable clamps are

supplied. Length from the

ceiling support and the top of the track needs to be determined by installer. A cable loop is created at the top of the cable length by a cable clamp. Be sure the installed cable does not contact any sharp edges; for example, loop the cable through an eyebolt attached to the ceiling. Be sure all of the threads of the square nuts are engaged to the U-bolt. The square nuts on the end of the U-bolt are slid into the top channel of the track. After U-bolt and cable are in their proper location

the nuts (7/16”wrench) on the U-bolts must be

tightened onto the track. A cable loop is created at the top of the track by the cable through the U-bolt

clamp. After adjusting the track height trim excess

cable as needed.

NOTE for both supports: Placing track at the proper elevation (this could be an angle for a sloped ceiling) and straightness is critical for a good installation.

Installation Guide:

U-Track

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Endcap

A U-track Endcap gives the U-track a nice nished look on cut ends. Endcap is friction-t and simply needs to be pressed into place. A sheet metal screw

should be used to hold the endcap in place.

Step 3 - 1 Row Style

Determine placement of track (both track path and elevation). The bottom of the U-Track must be mounted 1.5” (38mm) for standard Glider and Cord-In is 0.5” (13mm) above the 12:00 location of the DuctSox.

Track supports are spaced between

5 to 8 ft (1524 to 2440mm) apart with a maximum of 8 ft (2440mm).

Additional Track Supports must also be mounted at both ends of continuous track runs for stabilization

(or as an alternative, the track can

be secured by mounting the ends

with threaded rod). The track support

cable will need to be mounted at

angles away from the sides of the track along with angled cables in-line with the track. See image above.

1.5” (38mm)

Standard

0.5” (13mm)

for Cord-In

T’s

There should be roughly 12” (305mm) from sidewall of DuctSox to the start of the branch track. Track too

close to the main run may cause premature failure due to abrasion from the track. Support around fabric

ttings may require additional track supports. NOTE: Offset distance of branch U-Track from main trunk is approximately half of the main trunk diameter plus 12” (305mm).

12”

(305mm)

12”

(305mm)

12”

(305mm)

Installation Guide:

U-Track

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Elbows

Radius track is manufactured at the same radius of the DuctSox, this is typically 1.5 times the diameter of

the DuctSox. For example, a 24” diameter DuctSox would have a radius track with a radius of 36”.

(74” x 1.5 = 36”)

Install at least one Track Support per radius section; in the center if possible.

Coupler will not go into radius track the full 6” (and it shouldn’t). Coupler must only be inserted into radius track 1.5”. This connection will only use one screw in the radius track portion. There will be 3” radius couplers when splicing radius-to-radius connections.)

Radius track will only work with DuctSox that are installed in

a true horizontal plane (Figure A).

Vertical elbows are supported by D-ring straps rather than

radius track (Figure B).

Figure A Figure B

Surface Mount Hanging Option

U-Track in the 1-row style can be installed to a ceiling surface by multiple options.

Surface Mount Clip: A specially designed clip that snaps to the top of the U-Track. This clip can be mounted straight to the ceiling. After mounting to the ceiling the U-Track can be pushed up into the

clip and fastened in place. U-Track should be supported every 4 to 6 ft (1220 to 1830mm) when used in

the Surface Mount Hanging option.

Optional T-Bar Clip: A T-Bar clip is riveted (by installing contractor)

to the Surface Mount clip. The U-Track is snapped to the Surface Mount clip and the bottom of the T-Bar ceiling support.

Installation Guide:

U-Track

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Step 3 – 2 Row Style

Determine placement of track (both track path and elevation). The bottom of the U-Track must be mounted “A” inches apart and “B” inches below the 12:00 location of the DuctSox (match this up to the chart and the drawing.) Track supports are spaced between 5 to 8 ft (1524 to 2440mm) apart with a maximum of 8 ft (2440mm). Additional Track Supports must also be mounted at both ends of continuous track runs for stabilization (or as an alternative, the track can be secured by mounting the ends with threaded rod). The

track support cable will need to be mounted at angles away from the sides of the track along with angled cables in-line with the track. See image below.

Diameter

(inches) A B

12 10.83 1.63

14 12.56 2.13

16 14.29 2.63

18 16.02 3.13

20 17.75 3.63

22 19.49 4.13

24 21.22 4.63

26 22.95 5.13

28 24.68 5.63

30 26.41 6.13

32 28.15 6.63

34 29.88 7.13

36 31. 61 7.63

38 33.34 8.13

40 35.07 8.63

42 36.81 9.13

44 38.54 9.63

46 40.27 10.13

48 42.00 10.63

50 43.73 11.13

52 45.47 11.63

54 47.20 12.13

56 48.93 12.63

58 50.66 13.13

60 52.39 13.63

62 54.13 14.13

64 55.86 14.63

66 57.59 15.13

68 59.32 15.63

70 61.05 16.13

72 62.79 16.63

74 64.52 17.1 3

76 66.25 17.63

78 67.98 18.13

80 69.72 18.63

82 71.45 19.13

84 73.18 19.63

Diameter

(mm) A B

305 275 41

356 319 54

406 363 67

457 407 79

508 451 92

559 495 105

610 539 117

660 583 130

711 627 143

762 671 156

813 715 168

864 759 181

914 803 194

965 8 47 206

1016 891 219

1067 935 232

1118 979 244

1168 1023 257

1219 1067 270

1270 1111 283

1321 1155 295

1372 1199 308

1422 1243 321

1473 1287 333

1524 1331 346

1575 1375 359

1626 1419 371

1676 1463 384

1727 1507 397

1778 1551 410

1829 1595 422

1880 1639 435

1930 1683 448

1981 1727 460

2032 1771 473

2083 1815 486

2134 1859 498

Installation Guide:

U-Track

Page 9

T’s

There should be roughly 12” (305mm) from sidewall of DuctSox to start of the branch track. Track too

close to the main run may cause premature failure due to abrasion from the track.

Support around fabric ttings may require additional track supports.

NOTE: Offset distance of branch U-Track from main trunk is approximately half of the main trunk diameter

plus 12” (305mm).

12”

(305mm)

12”

(305mm)

12”

(305mm)

Installation Guide:

U-Track

Page 10

Elbows

Radius tracks are manufactured to match the radius of the DuctSox. This is typically 1.5 times the

diameter of the DuctSox. For example, the inside radius track of a 24” diameter DuctSox would have a radius of 25.6”.

24” x 1.07 = 25.6 ((24” x 1.5) - (24”/2 x .866) = 25.6”)

And the outside radius track of a 24” diameter DuctSox would have a radius of 46.4”.

24” x 1.93 = 46.4” ((24” x 1.5) + (24”/2 x .866) = 46.4”)

Install at least one support per radius section, in the center if possible.

Coupler will not go into radius track the full 6” (and it shouldn’t). Coupler must only be inserted into radius track 1.5”( this connection will only use one screw in the radius track portion. There will be 3” radius couplers when splicing radius-to-radius connections.)

Radius track will only work with DuctSox that are installed in a true horizontal plane (Figure A).

Vertical elbows are supported by D-ring straps rather than radius track (Figure B).

Figure A Figure B

Installation Guide:

U-Track

Page 11

Step 3 – 3 Row Style (10, 2, and 12)

Determine placement of track (both track path and elevation). The bottom of the U-Track must be mounted “A” inches apart and either “B” inches or 1.5” (38mm) below the 12:00 location of the DuctSox. Track supports are spaced between 5 to 8 ft (1524 to 2440mm) apart with a maximum of 8 ft (2440mm). Additional Track Supports must also be mounted at both ends of continuous track runs for stabilization (or as an alternative, the track can be secured by mounting the ends with threaded rod). The track support

cable will need to be mounted at angles away from the sides of the track along with angled cables in-line with the track. See image below.

Diameter

(inches) A B

12 10.83 1.63

14 12.56 2.13

16 14.29 2.63

18 16.02 3.13

20 17.75 3.63

22 19.49 4.13

24 21.22 4.63

26 22.95 5.13

28 24.68 5.63

30 26.41 6.13

32 28.15 6.63

34 29.88 7.13

36 31. 61 7.63

38 33.34 8.13

40 35.07 8.63

42 36.81 9.13

44 38.54 9.63

46 40.27 10.13

48 42.00 10.63

50 43.73 11.13

52 45.47 11.63

54 47.20 12.13

56 48.93 12.63

58 50.66 13.13

60 52.39 13.63

62 54.13 14.13

64 55.86 14.63

66 57.59 15.13

68 59.32 15.63

70 61.05 16.13

72 62.79 16.63

74 64.52 17.1 3

76 66.25 17.63

78 67.98 18.13

80 69.72 18.63

82 71.45 19.13

84 73.18 19.63

Diameter

(mm) A B

305 275 41

356 319 54

406 363 67

457 407 79

508 451 92

559 495 105

610 539 117

660 583 130

711 627 143

762 671 156

813 715 168

864 759 181

914 803 194

965 8 47 206

1016 891 219

1067 935 232

1118 979 244

1168 1023 257

1219 1067 270

1270 1111 283

1321 1155 295

1372 1199 308

1422 1243 321

1473 1287 333

1524 1331 346

1575 1375 359

1626 1419 371

1676 1463 384

1727 1507 397

1778 1551 410

1829 1595 422

1880 1639 435

1930 1683 448

1981 1727 460

2032 1771 473

2083 1815 486

2134 1859 498

1.5” (38mm)

Installation Guide:

U-Track

Page 12

T’s

There should be roughly 12” (305mm) from sidewall of DuctSox to start of the branch track. Track too

close to the main run may cause premature failure due to abrasion from the track.

Support around fabric ttings may require additional track supports.

NOTE: Offset distance of branch U-Track from main truck is approximately half of the main trunk diameter

plus 12” (305mm).

12”

(305mm)

12”

(305mm)

12”

(305mm)

Installation Guide:

U-Track

Page 13

Elbows

Radius tracks are manufactured to match the radius of the DuctSox. This is typically 1.5 times the diameter of the DuctSox.

For example, the inside radius track of a 74” diameter DuctSox would have a radius of 79.2”.

74” x 1.07 = 79.2” ((74” x 1.5) - (74”/2 x .866) = 79.2”)

The center 12:00 radius track would have a radius of 111”.

(74” x 1.5 = 111”)

And the outside radius track of a 74” diameter DuctSox would have a radius of 142.8”.

74” x 1.93 = 142.8” ((74” x 1.5) + (74”/2 x .866) = 142.8”)

Install at least one support per radius section, in the center if possible.

Coupler will not go into radius track the full 6” (150mm) and it shouldn’t. Coupler must only be inserted into radius track 1.5” (38mm). This connection will only use one screw in the radius track portion. There will be 3” (51mm) radius couplers when splicing radius-to-radius connections.

Radius track will only work with DuctSox that are installed in a true horizontal plane (Figure A).

Vertical elbows are supported by D-ring straps rather than radius track (Figure B).

Figure A Figure B

Installation Guide:

U-Track

Page 14

Step 4

Install DuctSox Fabric. DuctSox Inlet must be attached to the metal collar using

screws (not included) through plastic patches on the Inlet Belt. Be sure to locate the zipper start and seam at the 12:00 orientation for proper alignment.

Slide Glider or Cord-In attachments of the DuctSox into the

U-track bottom channel. Unzip ttings and slide them in

place independently of the straight sections. Close all zipper

connections before moving to Step 5.

Cord-In

Glider

Step 5

Start Up AHU. Turn on the AHU and inate the DuctSox System. Check all Gliders and sections to ensure

system is inating properly. If required, move Gliders to eliminate puckering at binding locations. If lengths do not t properly, double check all eld measurements and compare to drawings. If all measurements are

correct, contact your DuctSox factory rep to discuss options.

Once system is properly adjusted, inate the system, pull the last Glider in each straight section (including straight sections between ttings), and secure tension using Track Stop Screws. Also, be sure to install a

Track Stop Screw into the U-Track at the Endcap Glider, at the Inlet Glider, and at each Glider immediately

adjacent to all ttings.

The Track Stop Screw is used to keep sections of DuctSox from moving

lengthwise in the U-track. They also are used to put a slight tension on straight

sections of DuctSox (straight sections may consist of more than one zippered section of DuctSox). The screw is tightened into the bottom channel to lock the

stop at locations where Gliders are to be locked in place. The Track Stop Screw is not used with a Cord-In DuctSox system.

If the system includes elbows or T’s, secure Gliders before and after these ttings. Failure to install DuctSox Systems correctly may void warranty.

Track Stop Screw

Step 6

Air Balancing. System must be balanced to design CFM and static pressure immediately after installation.

Most DuctSox Systems include a zipper at the inlet location for easy access to monitor ow.

If the fabric is uttering after balancing, please contact your factory rep immediately. Solutions to the uttering include adjusting the Adjustable Flow Device (AFD), adding AFDs, or other solutions that would result in a less turbulent airow.

Installation Guide:

U-Track

Page 15

Laundering Instructions

Sedona-Xm, TufTex, Verona, DuraTex, Microbe-X, Rx, and Stat-X fabrics:

• Remove the DuctSox fabric from your system, being sure to unzip all sections. Take care in recording

where each section was installed.

• Turn soiled side out, soak in cold water for 30 minutes.

• Wash cold, gentle cycle.

• Rinse thoroughly (repeat cycle if water/DuctSox still soiled).

• Drip dry or no-heat tumble dry.

Installation Guide:

U-Track

Page 16

If any questions arise regarding the installation of your

U-Track System, contact us.

866-382-8769 or 563-588-5300

Ph: 866-382-8769 or 563-588-5300

9866 Kapp Court

www.ductsox.com

Peosta, IA 52068 Fax: 563-588-5330

DSUTRKIG0911B