Vetter Ultra Flat Bags STec 10 bar User Manual

Page 1
Emergency Pneumatics.
Operating InstructionS
VETTER Ultra Flat Bags S.Tec 10 bar
Article No. 9987054002 | © Vetter GmbH I 07/14 I Changes and errors excepted.
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Vetter Ultra Flat Bags S.Tec 10 bar
Contents
1. Important preliminary remarks ....................................2
2.1 Other accessories ...........................................4
2.2 Vetter safety coupling system ...............................5
2.3 Product description .........................................5
2.4 Correct usage ...............................................7
2.5 Safety instructions ..........................................7
3.1 Preparations for operation ..................................9
3.2 Application instructions .....................................9
4.1 Operation with compressed bottles .........................9
4.2 Operation with other sources of compressed air ........... 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. Elimination of defects ........................................... 12
6. Repetitive tests .................................................12
7. Technical data ..................................................13
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1. Important preliminary remarks
Only the knowledge and exact observance of these operating ins­tructions guarantee correct and professional operation, produces the greatest possible use and ensures any claims made within the scope of the Vetter guarantee.
The handling of the Vetter Ultra Flat Bags S.Tec is only to be made by trained persons using the operating instructions of the manu­facturer and the information from the user. 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 set
a. Ultra Flat Bags S.Tec 10 bar
The selection of bag size must correspond to operation require­ments. There are 4 sizes available from 1.1 to 11.6 t.
b. Ination hoses
In order to inate Vetter Ultra Flat Bags S.Tec from a safe position for the operator, there are ination hoses available with lengths of 5 m and 10 m. The hose colours in RED and YELLOW are used exclusively to assist the operator in recognizing the correct side when controlling the Vetter Ultra Flat Bags S.Tec.
c. Air CU (Control Unit) 10 bar deadman
Connect the ination hoses on the output couplings on the rear side of the controller. Connect the air suppply to the input coup­ling on the side. Move the switching lever to the front in order to inate the Ultra Flat Bags S.Tec. In doing this, observe the corres­ponding manometer and the load.
When the required operating pressure for the lifting power or lift height is reached, terminate the ination sequence by releasing the lever. The switching lever automatically returns back to the zero position (dead-man switching). The integrated safety valve activates automatically as soon as the maximum operating pres­sure of 10 bar is exceeded when inating or when there is a sud­den increase in bag pressure caused by an unintended loading of the bag.
The activation tolerance for opening and closing of the safety valve must only be a maximum of +/- 10%.
Press the switching lever in the opposite direction in order to de­ate the bag or to lower the load.
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Vetter Ultra Flat Bags S.Tec 10 bar
Additional information for illuminated control element Air CU 10 bar Totmann lighting
1
Dierent couplings!
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 controller 10 bar with dead-man switching,
1
2
aluminium
Press the lower button (1) in order to inate the bag. After release, the press-button returns again to the zero position and interrupts the ination sequence. Press the upper button (2) in order to de­ate.
e. Single controller 10 bar with dead-man switching, aluminium
If only one Ultra Flat Bag S.Tec is used for operation then this can be controlled with a single controller.
Inventory check
On acceptance of the Ultra Flat Bags S.Tec equipment a check is to be made to see if the delivery is complete according to the delive­ry note. In addition to this a visual check and function test is to be made according to the operating instructions.
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2.1 Other accessories
Pos. Article No. Description
1
or 1600 0262 00
2
3
4
5
1600 0261 00
1600 0108 00
1600 0199 00
1600 0091 00
1600 0145 00
Pressure regulator 200/300 bar
US Version 4500 psi (not compatible with below mentioned compressed air bottles)
Comp. air bottle
6 l / 300 bar
Comp. air bottle 9 l / 300 bar
Dual connector
300 bar
Pressure regulator
6
7
8
1600 0120 00
1600 0087 00 Hand pump (7)
1600 0094 00 Foot pump (8)
Adapter for construction site compressor
7
8
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Vetter Ultra Flat Bags S.Tec 10 bar
2.2 Vetter safety coupling system
3
2
1
a. Input coupling of the controller
Connect the air supply hose or the connection hose of the pres­sure regulator to the nipple of the input coupling (1) on the cont­roller pushing the nipple solidly into the coupling until the ratchet action can be felt. In order to ensure that it is correctly connected: turn the brass sleeve (2) of the coupling opposite to the safety pin (3).
b. Ination hoses
To connect the ination hoses to the corresponding controller or to the Ultra Flat Bags S.Tec, press the hoses or bag nipple solidly into the coupling until the ratchet action can be felt. The coupling sleeve must be seated on the support ring without any gap (1). To release the connection (only in the pressure-free condition) the nipple must be solidly pressed against the spring pressure in the
1
coupling. At the same time the coupling sleeve must be pushed back. The coupling then releases.
c. Ination with an 8 bar ination device
The Ultra Flat Bags S.Tec safety coupling system cannot be used for ination with other ination devices. However, should it be necessary, in exceptional cases, to inate with the Vetter 8 bar sys­tem then the 10 bar / 8 bar adapter must be used.
2.3 Product description
Vetter Ultra Flat Bags S.Tec 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 inuence 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 S.Tec is subjected to a plant accep­tance test within the scope of quality assurance.
Material of the Ultra Flat Bags S.Tec : CR/Aramide, hot vulca­nized
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Temperature resistance of Ultra Flat Bags S.Tec :
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 Bags S.Tec can be damaged by damage made to the bag surface, e.g. cuts, cracks, punctures or by the eects 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 eective 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 S.Tec will only be reached in the unloaded state.
In case the lifting power produced by the Ultra Flat Bag S.Tec is not sucient, depending on the lift height, then a number of S.Tec Bags can be placed next to each other.
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Vetter Ultra Flat Bags S.Tec 10 bar
In case the lifting height of an Ultra Flat Bag S.Tec is not sucient 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 S.Tec.
However the lifting power only corresponds to that of the smaller bag. Basically, the lower bag should always be inated rst.
Sequence: large bag below, small bag on top! Never place 3 or more bags over each other!
An Ultra Flat Bag S.Tec under load can be compared to a spring under tension with respect to its behavour. As soon as the Ultra Flat Bag S.Tec is suddenly released, e.g. by slipping, load break or anything similar then there will be spontaneous catapulting out­wards of the Ultra Flat Bag S.Tec.
Never stand in front of the Ultra Flat Bag S.Tec! This is an area of danger!
2.4 Correct usage
First and formost, Ultra Flat Bags S.Tec are pneumatic rescue de­vices for rescue services (re services) in which trapped persons can be freed and access can be obtained for rescue and carrying our counter-measures as well as other similar measures. In additi­on to this Ultra Flat Bags S.Tec can be used as working equipment for lifting or movement of loads. Ultra Flat Bags S.Tec 10 bar 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 Bag S.Tec system is cold-resistant to -20 °C and heat-resistant up to +55 °C.
2.5 Safety instructions
Pre-specied 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 S.Tec are only to be used with compressed air, under no circumstances are they to be used with inammable gases or aggressively acting gases. Vetter Ultra Flat Bags S.Tec are only to be inated with original Vetter ination 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 (specications from the manufac­turer, national regulations).
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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.
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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 S.Tec, 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 eects 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!
An Ultra Flat Bag S.Tec can burst under adverse conditions with incorrect operation, incorrect handling or by manipulation on the controller and/or ination hose (problems concerning pressure waves and sound waves, uncontrolled movement)!
Vetter Ultra Flat Bags S.Tec are not suited for use in explosion endangered zones! Special versions are possible on request!
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Vetter Ultra Flat Bags S.Tec 10 bar
3. Preparing the product for use
3.1 Preparations for operation
Remove the Ultra Flat Bag S.Tec from the vehicle. Prepare the ina­tion device. Ensure that sucient air supply is available.
Only perfectly working and tested Ultra Flat Bags S.Tec systems are to be used!
From case to case, the head of operations is to decide, within his area of responsibility, about the method to be used for the opera­tion as well as the operating instructions of the user.
3.2 Application instructions
Insert the Ultra Flat Bag S.Tec at a suitable position so that at least 75% of the support surface of the bag 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 S.Tec because it could be catapulted outwards under unfavourable conditions.
4. Operating instructions
4.1 Operation with compressed bottles
Connect the pressure reducer to the compressed air bottle
4
3
1
9
8
6
2
5
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 10/12 bar with the re­gulation bar (5) (indication of the reduced pressure on the back pressure manometer (6)).
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).
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Open the hand wheel (2) of the pressure reducer.
7
The lifting bag system is ready for operation.
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4.2 Operation with other sources of com­pressed air
Basically, every source of air available can be used for operation of the Ultra Flat Bags S.Tec as long as the pressure does not exceed 12 bar and that the air is free of oil as far as possible. 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 7
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
10
Remember! Ensure that the truck does not roll, use brake blocks!
3. Truck tyre ination device adapter For tapping o air from the so-called tyre ination bottle near the brake.
Remember! The tyre ination connection must be ensu­red by a safety valve as a standard (blow-o pressure ap­proximately 7.5 bar)!
4. Truck tyre valve Ination with a normal hand or foot pump as well as other air supplies for tyre ination.
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 S.Tec 10 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 deation 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 S.Tec are subject to natural aging the same as any other rubber products. The aging of the material is initially indi­cated by the loss of exibility which especially becomes aparent with the appearance of so-called aging cracks. If these cracks pro­pagate in the cover material so that the ARAMIDE reinforcement is no longer protected by the cover layer then this can lead to a crack networks forming on the surface and thus cause bursting of the bag.
The experiences gained in the last decade have clearly shown that the general failure rate with rubber products considerably increases from a period exceeding 15 years. Therefore Ultra Flat Bags S.Tec should be replaced after 15 years, 18 years is the maxi­mum. The danger for rescue services when using aged Ultra Flat Bags S.Tec should never be underestimated for welfare reasons. It should be stressed that although there is currently no regulation about the maximum time limit, the responsibility rests fairly and squarely with the user and the inspector commissioned by him.
4.5 Care, maintenance and storage
The lifting bag equipment is to be cleaned after every operation. Cleaning is normally made with warm water and a soap solution.
Cleaning must never be carried out with chemicals and high-pressure hot water devices.
Drying is to be 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.
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DIN 7716 is to be observed for long-term storage.
The VETTER Guarantee is 36 months for Ultra Flat Bags S.Tec.
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5. Elimination of defects
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.
If the seal or the seal plate on the safety valve of the controller on the upper part of the valve has been removed then correct operation is no longer 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 S.Tec 10 bar
7. Technical data
Ultra Flat Bags S.Tec 10 bar
Unit
Art. No.
Lift power
Lift height
Insertion height*
Dimensions
Operating max. pressure
Test pressure
Air requirement at 10 bar/145 psi
Nominal capacity
Burst pressure, min.
Weight ca.
to
US tons
cm
inch
cm
inch
cm
inch
bar
psi
bar
psi
l
cu.ft.
l
cu.ft.
bar
psi
kg
lbs
UF 1 S.Tec UF 4 S.Tec UF 7 S.Tec UF 12 S.Tec
1315006000 1315006100 1315006200 1315005900
1.1 3.8 7.0 11.6
1.2 4.2 7.7 12.8
7.5 12.0 16.5 20.3
3.0 4.7 6.5 8.0
1.6 1.6 1.6 1.6
0.6 0.6 0.6 0.6
14 x 13 25.5 x 20 29.5 x 29.5 37 x 37
5.5 x 5.1 10 x 7.9 11.6 x 11.6 14.6 x 14.6
10 10 10 10
145 145 145 145
16 16 16 16
232 232 232 232
3.85 24.75 48.4 92.95
0.1 0.9 1.7 3.3
0.35 2.25 4.40 8.45
0.01 0.08 0.16 0.30
40 40 40 40
580 580 580 580
0.4 1.0 1.7 2.4
0.88 2.20 3.75 5.29
* around valve + 6 mm (0.2 inch)
All rights reserved for technical changes within the scope of product improvement.
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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 VETTER Ultra Flat Bags S.Tec (Aramid) 10 bar for lifting and lowering of 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 Ocial Journal of the European Union:
DIN EN ISO 12100
EN 13731
Applied national standards and technical specications:
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, 03.07.2014
(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
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.9987054002 | © Vetter GmbH I 07/14 I Changes and errors excepted. I Made in Germany
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