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Emergency Pneumatics.
Operating Instructions
VETTER Ultra Flat Bags 8.0 bar
Article No. 9987023501 | © Vetter GmbH I 07/14 I Changes and errors excepted.
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Vetter Ultra Flat Bags 8.0 bar
Contents
1. Important preliminary remarks ....................................2
2. Description of the product ........................................2
2.1 Description of the set .......................................2
2.2 Additional accessories ......................................4
2.3 The Vetter safety coupling system ...........................5
2.4 Description of the product ..................................6
2.5 Correct handling and usage .................................7
2.6 Safety instructions ..........................................7
3. Preparing the product for use .....................................9
3.1 Preparations for operation ..................................9
3.2 Application instructions .....................................9
4. Operating Instructions ............................................9
4.1 Operation with compressed air bottles ......................9
4.2 Operation with other compressed air supplies. . . . . . . . . . . . . 10
4.3 Dismantling of the lifting bag system after use .............11
4.4 Limit for the period of use ................................. 11
4.5 Care, maintenance and storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5. Trouble-shooting for faults ......................................12
6. Repetitive tests .................................................12
7. Technical Data ..................................................13
8. List of possible dangers according to EN 12100-1 and EN 12100-2 14
EC Conformity Declaration (available on request) ...................15
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1. Important preliminary remarks
Only knowledge and the exact observance of this operating manual guarantee correct and reliable operation, achieve the best
possible usage and ensure any claims made within the framework
of the Vetter guarantee.
Only sta are to use Vetter Ultra Flat Bags who have been instructed in their use by the manufacturer‘s operating manual and
operating instructions.
The disposal of discarded lifting bags is to be carried out according to disposal regulations valid for the region.
The operating instructions given here are to be regarded as part
of the product and are to be kept for the complete life duration of
the product. In case the product should be passed on to a successive user then the operating instructions must also be included.
2. Description of the product
2.1 Description of the set
a. Ultra Flat Bags
Bag size selection is made according to the task. There are 4 dierent sizes from 1.1 t to 9.6 tons.
b. Ination hoses
There are ination hoses available (5 m and 10 m in length) which
enable the user to control the Ultra Flat Bags from a safe position.
The colours of the hoses, RED and YELLOW, avoid any confusion
during control of the dierent sides (inlets and outlets) of Ultra
Flat Bags.
c. Air CU (Control Unit) 8 bar deadman
Connect the ination hoses to the outlet coupling on the rear side
of the controller. Connect the air supply to the inlet coupling on
the side. Move the control lever to the front in order to inate the
Ultra Flat Bag. In doing this, observe the corresponding manometers and the load. Release the control lever, thus ending the ination process, when the required operating pressure for the lift
power or lift height is reached.
The control lever automatically returns to the center position
(zero) when released (deadman switched).
The built-in safety valve automatically activates when the bag is
over-inated above the maximum operating pressure of 8 bar or
when there is an unforeseen additional burden of the bag.
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Vetter Ultra Flat Bags 8.0 bar
The activation tolerance for opening and closing of the
safety valve can be +/- 10 %.
Press the control lever in the opposite direction in order to deate
the bag or to reduce the load.
1
Dierent couplings!
Additional information for illuminated control element
Air CU 8 bar deadman lighting
The lighting of the control element illuminates all couplings,
switch levers and manometers. It is switched on and o with
switch (1) on the side.
The control element is supplied by a 9 V block battery. Since the
entire lifting bag system is designed for a temperature range of
-20 °C to +55 °C, only batteries with this temperature range are
allowed to be used. Based on the current state of the art, only lithium batteries meet this requirement.
To insert the battery, unscrew the battery compartment, replace
the old battery with a new one and screw the battery compartment back together.
Control elements with lighting come under the German Law on
electrical and electronic devices (ElektroG) of 24 March 2005 for
implementation of the EC Directive 2002/96/EC on electrical and
electronic waste – WEEE Directive.
The label attached to the battery compartment cover points
out that the electronic components in this product must not be
handled as domestic waste; they have to be returned to the manufacturer (return freight paid) for recycling.
d. Dual deadman controller 8 bar, aluminium
Press down the upper button (1) in order to inate the bag. Ina-
1
2
tion is stopped when the button is released and it returns back to
the zero position. The bag is released by pressing the lower button (2).
e. Single deadman controller 8 bar, aluminium
The single deadman controller, on the left, can be used when only
one Ultra Flat Bag is to be used.
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The single and dual controllers in the 8 bar tting version do
not correspond to the requirements of the Fire Service standard DIN EN 13 731.
f. Dual controller 8 bar, tting
Controller with ination regulator using a ball valve WITHOUT deadman
switching. To empty the bag, open the head of the safety valve (1) by
turning to the left. Close the safety valve by turning to the right after
deation.
g. Single controller 8 bar, tting
The same version as described in f) but used for the control of only one
Ultra Flat Bag.
Inventory of items
An inventory and check of all items in the delivery package is to be made
according to the delivery documentation when acceptance of the Ultra
Flat Bags equipment is carried out. A visual check and function check is
also to be made as specied in the operating manual.
1
1
2.2 Additional accessories
Pos.
Article No. Description
Pressure regulator 200/300 bar
US Version 4500 psi
(not compatible with below
mentioned compressed air
bottles)
Comp. air bottle
Comp. air bottle 9 l / 300 bar
Dual connector
300 bar
1
or 1600 0262 00
2
3
4
1600 0261 00
1600 0108 00
1600 0199 00
1600 0091 00
6 l / 300 bar
5
6
1600 0145 00
1600 0120 00
Pressure regulator
Adapter for construction site
compressor
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Vetter Ultra Flat Bags 8.0 bar
Pos.
Article No. Description
7
8
3
2.3 The Vetter safety coupling system
1600 0087 00 Hand pump (7)
1600 0094 00 Foot pump (8)
7
8
a. Inlet coupling controller
Connect the air supply hose, resp. connection hose of the pressure re-
2
1
ducer, to the plug nipple of the inlet coupling on the controller. In doing
this, rmly press the nipple into the coupling until it latches in. Turn the
brass sleeve of the coupling opposite to the safety pin for additional safety.
b. 8 bar ination coupling
Firmly press the hose, resp. bag nipple, into the coupling until it latches
in order to connect the ination hose with the corresponding controller,
resp. with the Ultra Flat Bag. The coupling sleeve must lay on the support
ring without any gap (1). The nipple must be rmly pressed against the
spring pressure in the coupling in order to release the connection (only
1
in pressure-free condition). At the same time, the coupling sleeve must
be pulled back. The connection is then released.
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2.4 Description of the product
Vetter Ultra Flat Bags are made by hand from high quality raw materials so that after completion, a seamless bag is produced. The
semi-nished product is vulcanized under the inuence of pressure and temperature and by doing this the individual layers bond
to form an elastomer body. After production has been nalized,
each Ultra Flat Bag is subjected to a plant acceptance test within
the scope of quality assurance.
Material of the Ultra Flat Bags: CR/Aramide, hot vulcanized
Temperature resistance of Ultra Flat Bags:
Cold resistance -40 °C
Cold exible -20 °C
Heat resistance long-term +90 °C
Heat resistance short-term +115 °C
The aramide layer on the Ultra Flat Bag can
be damaged by damage made to the bag
surface, e.g. cuts, cracks, punctures or by
the eects of ozone.
Therefore with a visual check after every operation, special attention is to be made to the following types of damage:
9 Damage by separation
9 Damage by cuts
9 Damage by punctures
9 Damage by heat and chemicals
Danger of bursting! If, when carrying out the
check, this type of damage is determined
then the bag is to be immediately taken
out of service. Repair is not possible.
In order to use the maximum lifting power, the total eective area,
i.e. the total area minus the edge area, must be completely under
the load to be lifted and that the bag must be taken to the maximum permitted operating pressure.
The bag develops a spherical shape (with rectangular or square
base) as the lift height increases. This is the reason why the contact area with the load decreases until at a max. bag curvature this
will be almost zero. The largest lift height of the Ultra Flat Bag will
only be reached in the unloaded state.
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Vetter Ultra Flat Bags 8.0 bar
In case the lifting power produced by the Ultra Flat Bag is not sufcient, depending on the lift height, then a number of Ultra Flat
Bags can be placed next to each other.
In case the lifting height of an Ultra Flat Bag is not sucient then a
maximum of 2 bags can be placed over each other. In this mode,
the lifting height is additive for both Ultra Flat Bags.
However the lifting power only corresponds to that of the smaller
bag. Basically, the lower bag should always be inated rst.
Sequence: large bag below,
small bag on top!
Never place 3 or more bags over each other!
An Ultra Flat Bag under load can be compared to a spring under
tension with respect to its behavour. As soon as the Ultra Flat Bag
is suddenly released, e.g. by slipping, load break or anything similar then there will be spontaneous catapulting outwards of the
Ultra Flat Bag.
Never stand in front of the Ultra Flat Bag!
This is an area of danger!
2.5 Correct handling and usage
The Ultra Flat Bag is primarily a pneumatic rescue device used by
the rescue services (e.g. re services) with which trapped people
can be freed, access gained for rescue and many other tasks. The
Ultra Flat Bag can also be used as a working device in order to lift
or move loads.
Ultra Flat Bags are subject to national requirements of the re
service sector. Further instruction information can be obtained
from the operating instructions of the user. The complete Ultra
Flat Bags system is cold-resistant to -20 °C and heat-resistant up
to +55 °C.
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2.6 Safety instructions
Pre-specied personal protective clothing is to be worn during
operation! For example: protective clothing, helmet, protective
gloves, protection for eyes and face, noise protection etc.
The national regulations in connection with lifting bag systems
and their use are to be observed. For example: DIN EN 13731,
national regulations. The Ultra Flat Bags are only to be used with
compressed air, under no circumstances are they to be used with
inammable gases or aggressively acting gases.
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Vetter Ultra Flat Bags are only to be inated with original Vetter
ination ttings because these were subjected to an acceptance
test by the manufacturer. The lifting bag system is to be tested
for perfect condition before and after use (specications from the
manufacturer, national regulations).
The lifted load is to be continually supported during the progessive lifting sequence. The stable condition of foundation support
material must always be observed during construction of the
foundation support.
Never position 3 or more bags on top of each
other!
Ensure load against slippage.
In order to fully use the strengths of the Ultra Flat Bag, the distance between load and bag should be at a minimum.
The foundation support must brace at
least the complete area of the bag and the
smallest edge length of the foundation
support must be larger than the height of
the foundation support. Metal must
never be place on metal!
Attention: danger of slipping!
With slippery ground (ice, snow, mud etc.) place anti-slip materials
under the bag in order to increase adhesion. Point-shaped loads
are to be avoided, e.g. construction claws or screws. Never place
the bags on sharp edges, hot or red hot components. Use suitable
temporary storages and cover the complete contact area of the
bag. Protect the bag against ying sparks during welding or separation work. Do not additionally load bags with such things as
hydraulic lifting devices, winches or falling loads.
Never remain beneath a lifted load, never hold
the load from below!
Remain at a distance!
Avoid shearing eects by squeezing of the bag when lowering the
load!
During operation never stand in front of
the bag but always to one side, because the
bag could catapult outwards under
unfavourable conditions!
The lifting sequence is to be stopped
immediately if there is a function failure!
A Ultra Flat Bag can burst under adverse conditions with incorrect
operation, incorrect handling or by manipulation on the controller and/or ination hose (problems concerning pressure waves
and sound waves, uncontrolled movement)!
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Vetter Ultra Flat Bags 8.0 bar
Vetter Ultra Flat Bags are not suited for use
in explosion endangered zones!
Special versions are possible on request!
3. Preparing the product for use
3.1 Preparations for operation
Remove Ultra Flat Bags from the vehicle. Prepare the ination device. Ensure sucient air supply.
Only perfectly operating and inspected
Ultra Flat Bags are to be used.
The method and type of application is to be decided from case to
case by the operation leader with his own area of responsibility as
well as the operating instructions of the user.
3.2 Application instructions
Move the lifting bag to a suitable position so that at least 75% of
the supporting bag area is under the load. Continually built up the
under-support for maintaining contact when the load is lifted during the lifting procedure. Never stand in front of the bag during
operation but to the side of the Ultra Flat Bag because it could be
catapulted outwards under unfavourable conditions.
4. Operating Instructions
4.1 Operation with compressed air bottles
4
3
1
6
2
5
Connect the pressure reducer to the compressed air bottle
200 bar or 300 bar using the tommy screw (1). Close the hand
wheel of the pressure reducer (2). Open the valve on the
bottle (3). The pre-pressure manometer (4) indicates the pressure
in the bottle.
Adjust the back pressure to approximately 10 bar with the regulation bar (5) (indication of the reduced pressure on the back pressure manometer (6)).
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9
8
7
Connect the air hose of the pressure reducer via the nipple to the
input coupling (7) of the controller. In doing this, press the nipple
into the coupling until you feel it lock in. For additional safety: turn
the brass sleeve (8) so that it is opposite the safety pin (9).
Open the hand wheel (2) of the pressure reducer.
The lifting bag system is ready for operation.
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4.2 Operation with other compressed air
supplies
Basically, any air supply which is available can be used for operation of Ultra Flat Bags as long as the pressure does not exceed 10
bar and the air is free of oil. Amongst others, the set of transition pieces (Art. No.: 1600 0125 01) with the following adapters are
available for operation with other air sources:
8 9
3
456
2 1
1. Truck compressed air connection, dual brake system.
For tapping air out of the trailer coupling head.
2. Dummy coupling
Seals o the control line of the brake system
7
10
Remember! Ensure that the truck does not roll, use brake
blocks!
3. Truck tyre ination device adapter
For tapping o air from the so-called tyre ination bottle near
the brake.
Remember! The tyre ination connection must be ensured by a safety valve as a standard (blow-o pressure approximately 7.5 bar)!
4. Truck tyre valve
Ination with a normal hand or foot pump as well as other air
supplies for tyre ination.
5. Truck tyre valve connection, can be clamped
For extracting air for the spare tyre.
6. Adapter for the local air pressure network.
7. Adapter Construction-site compressor
8. Air supply hose, 10 m, green.
9. Air supply hose, 10 m, green, with blocking valve.
10. Case, red
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Vetter Ultra Flat Bags 8.0 bar
4.3 Dismantling of the lifting bag system
after use
Dismantling of the lifting bag system is carried out after ensuring
the lifted load and complete deation of the lifting bag system,
including dismantling of all accessory parts in the reverse order.
4.4 Limit for the period of use
Ultra Flat Bags are subject, the same as other rubber products, to
natural aging. The rst sign of material aging is the loss of exibility, this is especially seen in the formation of „age cracks“. If these cracks propagate so far along the upper layer so that the supporting cord layer (ARAMIDE) is no longer fully insulated then this
can quickly limit the tear resistance of the bag wall. This can cause
wall tearing and thus lead of bursting. The experiences over the
past decade have clearly shown that the failure rate in general for
rubber products considerably increases with application periods
exceeding 15 years. Therefore Ultra Flat Bags should be replaced
after 15 to 18 years of use at the latest. The danger for operational
services using over-aged Ultra Flat Bags must never be under-estimated, alone due to the consideration aspect. Although at present there is no regulation about the time limit for the maximum
period of use, the responsibility for this lies wholy and soly with
the user, resp. the person who has been commissioned by him to
carry out testing.
4.5 Care, maintenance and storage
The lifting bag equipment is to be cleaned after each operation.
Cleaning is normally carried out with warm water and a detergent.
Cleaning must never be carried out with
a chemical cleaning agent and never
with high-pressure hot water devices.
Drying is made at normal room temperature. A bag is to be immediately discarded if, during inspection, any sign of damage is established (refer to Page 6). Repair is not possible. If needed, components such as manometers, safety valves and piston valves can be
exchanged. Hose couplings and nipples can also be exchanged.
After necessary repair, the equipment is to be checked according
to the repetitive tests. This special test is also to be documented.
DIN 7716 is to be observed for long-term storage.
The VETTER guarantee is 36 months for Mini-Lifting Bags.
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5. Trouble-shooting for faults
If the safety valve blows too early because of foreign body penetration caught up inside then the blow-o valve is to be fully
opened on the head of safety valve by turning counter-clockwise
so that the compressed air can escape. If, due to this, the foreign
body is not removed then the upper part of the safety valve is to
be unscrewed when the safety valve is disassembled. To do this,
position the pipe wrench in the centre and unscrew by turning to
the left.
Carefully take out the valve ball and remove foreign body. Firmly
screw on the upper part of the valve again, assemble the safety
valve and check operation. The set pressure must not be changed.
Should the sealing or sealing plate on
the upper part of the valve be removed
then correct operation can no longer
be guaranteed.
The safety valve is to be exchanged.
6. Repetitive tests
Lifting bag systems are to be subjected to repetitive tests according to DIN EN 13731 and national regulations (e.g. GUV-G 9102).
9 Testing on acceptance
Testing for completeness by the person/people delegated by
the user.
Visual check and operation test by a trained person according to the operation manual.
9 Visual check and operation test after each application/use by
the user.
This test is to be documented.
9 At least once every year the lifting bag system is to be given a
visual check and operation test by a trained person according
DIN EN 13731 and national regulations.
This test is to be documented.
9 At least every 5 years or if there is any doubt about the safety
or reliability, the lifting bag system is to be given a pressure
test by the manufacturer or a trained person with further training of the manufacturer, according to DIN EN 13731 and national regulations.
The user is responsible for the correct and professional execution
of the repetitive tests!
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Vetter Ultra Flat Bags 8.0 bar
7. Technical Data
Ultra Flat Bags with ARAMIDE reinforcement
Type UF 1 UF 3 UF 6 UF 10
Item No. 1314018800 1314018700 1314018600 1314020700
Lift power,max to 1.0 3.29 6.36 9.60
Lift height, max cm 7,5 12.0 16.5 20.3
Size cm 14 x 13 25.5 x 20.0 29.5 x 29.5 36 x 36
Insertion height cm 1.2 1.2 1.2 1.2
Nom. content l 0.30 1.8 4.2 8.3
Air capacity l 2.8 15.9 37.8 74.2
Operating
pressure max.
Test pressure bar 12 12 12 12
bar 8 8 8 8
Weight kg 0.26 0.74 1.3 1.7
All rights reserved for technical changes within the scope of product improvement.
Ultra Flat Bag UF 1 Ultra Flat Bag UF 6
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Ultra Flat Bag UF 3 Ultra Flat Bag UF 10
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8. List of possible dangers according to
EN 12100-1 and EN 12100-2
Danger see Page
A.1 Mechanical dangers
1.1 Danger by squeezing 3 / 4 / 8 / 9
1.7 Danger by puncturing 4 / 6
1.9 Danger by catapulting out 3 / 4 / 8 / 9
A.2 Danger due to noise
2.1 Injury to hearing 3
2.2 Impairment of speech 3
A.3 Material danger
3.1 Explosion 3
A.4 Danger due to negligence of ergonomic principles
4.1 Positions which impair health 4
4.2 Negligent use of personal protection devices 3
4.3 Mental over and under demands, stress etc. 3
4.4 Human error 3
4.5 Unfavourable arrangement of visual indications 5
A.5 Unintended movements
5.1 Faults/erroneous functions of the control elements 9
A.6 Mechanical failure
6.1 Failure of energy supplies 9 / 12
6.2 Failure of the control device 9 / 12
6.3 Loss of stability 3 / 8
A.7 Additional dangers
7.3 due to the control device 8 / 9
7.5 Movements 8 / 9
7.8 Negligent use 8 / 9
7.9 Movement of parts from the stationary position 8 / 9
7.10 Missing or insucient visual or acoustic warning devices 11 / 12
7.11 Insucient instructions for the user 3
7.12 Falling loads 11
7.13 Missing stability 8 / 9
7.14 Uncontrolled sudden movements 8 / 9
7.15 Uncontrolled/unintended load movement 8 / 9
7.16 Insucient holding devices 3 / 8
7.17 Insucient solidity of parts 3 / 7
7.18 Exceptional conditions during assembly, testing, use, maintenance
7.19 The eects of loads on persons 3
7.20 Dangers due to negligence of ergonomic principles (load
bumping)
7.21 Fire and explosion 3
7.22 Control failure 3
3 / 9
11
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Vetter Ultra Flat Bags 8.0 bar
EC Conformity Declaration (available on request)
in accordance with Directive 2006/42/EC
Manufacturer name and address
Vetter GmbH
A Unit of IDEX Corporation
Blatzheimer Str. 10 - 12
53909 Zülpich
We hereby declare that the Ultra Flat Bags for lifting and lowering loads
Type: ______________
Serial-No.: ______________
Model: ______________
(refer to equipment label, to be entered by the customer)
meets the following relevant provisions:
Directive 2006/42/EC on Machinery
Applied harmonised standards, references to which have been published in the
Ocial Journal of the European Union:
DIN EN ISO 12100
EN 13731
Applied national standards and technical specications:
Authorised representative for the compilation of technical documents:
Vetter GmbH
A Unit of IDEX Corporation
Blatzheimer Str. 10 - 12
53909 Zülpich
This EC Conformity Declaration was issued:
Zülpich, 23.07.2014
(Place, Date, Signature)
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Place your trust in emergency pneumatics!
We are the company who can help you, nd a solution to your problem!
Vetter GmbH
A Unit of IDEX Corporation
Sales Germany
Blatzheimer Str. 10 - 12
D-53909 Zülpich
Germany
www.vetter.de
Tel.: +49 (0) 22 52 / 30 08-0
Fax: +49 (0) 22 52 / 30 08-590
Mail: vetter.rescue@idexcorp.com
Article No. 9987023501 | © Vetter GmbH I 07/14 I Changes and errors excepted. I Made in Germany
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