Installation Instructions Document No. 546-00449 August 10, 2004 UniTrak Sensor Assembly Kit Horizontal, Vertical, and Combination Sashes Product Description The UniTrak™ Sensor Assembly Kit contains the hardware to complete one fume hood sensor assembly. Fume hoods with multiple vertical sashes, including walk-in fume hoods, require multiple UniTrak kits. The following table lists what is included for Vertical and Horizontal kits (See Figure 1): Item Vertical Horizontal Adhesive-backed UniTrak sensor strips with actuator car and three-pin sensor end connector. 1 2 Three-pin sensor cable assembly. 1 2 Unbent linkages 1 5 Actuator materials: polyvinyl chloride (PVC) and stainless steel. 1 4 Sensor strip materials: polyester and PVC plastics. 1 2 NOTE: Fume hoods may have dimensional variations; however, these variations will have minimal impact on UniTrak Sensor Assembly Kit installations. Product Numbers Kit Number Sensor Length- Active/Usable inches (mm) Sensor Length- Installed inches (mm) Horizontal * 546-00495 34 (863.6) 39.3 (998) 546-00493 43 (1092) 48.3 (1227) 546-00492 52 (1321) 57.3 (1455) 546-00491 70 (1778) 75.3 (1913) 546-00442 84 (2134) 89.8 (2280) Vertical * 546-00490 30 (762) 33.3 (846) 546-00489 32 (813) 35.3 (897) 546-00488 35 (889) 39.3 (998) 546-00487 40 (1016) 40.3 (1024) 546-00486 44 (1118) 48.3 (1227) 546-00485 53 (1346) 57.3 (1455) 546-00484 71 (1803) 75.3 (1913) 546-00443 85 (2159) 89.8 (2281) Sash Sensor Shield ** Shield Length-Installed inches (millimeters) 546-00565 37.3 (947) 546-00566 46.3 (1176) 546-00567 55.3 (1405) 546-00568 73.3 (1862) 546-00569 87.8 (2230) *The following kits must be ordered separately. ** One shield per sensor track is included with each sensor kit. 546-00041 Trim tool kit 546-00215 10 vertical unbent linkages 546-00494 10 horizontal unbent linkages 546-00558 Linkage forming tool Item Number 546-00449-03, Rev. 010 Page 1 of 13 Document No. 546-00449 Installation Instructions August 10, 2004 SENSOR SASH SHIELD DECORATIVE COVER PLATE SENSOR CONNECTOR VERTICAL SASH LINKAGE HORIZONTAL SASH LINKAGE CONNECTOR ACTUATOR BLOCK UNITRAK SENSOR CONNECTOR ACTUATOR BLOCK REMEMBER TO CLOSE THE SASH REMEMBER TO CLOSE THE SASH FUM0376R1 LINKAGE MOUNTING PLATE Figure 1. UniTrak Assembly Kit. Warning/Caution Notations WARNING: Personal injury/loss of life may occur if you do not perform a procedure as specified. CAUTION: Equipment damage or loss of data may occur if you do not perform a procedure as specified. Required Tools (H = Horizontal; V = Vertical) H V • 6-foot ladder • Flat-blade screwdriver • Medium duty electric drill • Permanent marking pen • Tape measure • Alcohol towelette • Wire cutters • Linkage-forming tool • 3/8-inch drill bit • Electrical tape • Portable vacuum cleaner • 3/32-inch carbide tip drill bit • 3/8-inch carbide tip drill bit • Trim tool kit Expected Installation Time • 50 minutes with factory bent linkage kit (horizontal) • 30 minutes (vertical) • 70 minutes without factory bent linkage kit (horizontal plus vertical) Page 2 of 13 Siemens Building Technologies, Inc. Document No. 546-00449 Installation Instructions August 10, 2004 Prerequisites • If this is your first UniTrak installation, read these instructions entirely before beginning. • The fume hood sash panels must be installed to ensure proper fit of the UniTrak sensor. • For retrofit installations, notify the laboratory safety officer that you will be working in the fume hood. Take the necessary precautions to have the fume hood cleaned, prepared and safety certified. WARNING: Do not proceed with these installation instructions until the fume hood has been cleaned and emptied of all hazardous substances including fumes, vapors, toxic materials, contaminants, chemicals, bacteria, etc. The following prerequisites apply to Vertical: • For best appearance, mount the UniTrak sensor on the inside of the fume hood. • The surface on which you mount the sensor strip should be smooth, flat, clean, and free of obstacles such as rivets, screw heads, nozzles, sash stops, and abrasives. • If corrosive fumes are to be exhausted, mount the UniTrak sensor on the outside of the fume hood. Instructions The UniTrak Sash Sensor Installation Instructions consist of the following tasks. Tasks 3 and 5 for the Vertical Install have separate instructions for outside and inside mountings of the UniTrak sensor. Tasks Horizontal Vertical 1 Measuring the Sash Opening N/A Step 1 (p. 3) 2 Mounting the UniTrak Step 1 (p. 5) Step 2 (p. 3) 3 Bending Linkages Step 2 (p. 8) Step 3 (p. 6) 4 Attaching Linkages to Sash Panels Step 3 (p. 10) Step 4 (p. 10) 5 Wiring Step 4 (p. 12) Step 5 (p. 11) 6 Installing the Sensor Shield Step 5 (p. 13) Step 6 (p. 13) CAUTION: Do not bend or kink the sensor strip, as this will damage the sensor. Bends in the sensor strip will cause errors in the sash measurement. Measuring the Sash Opening (Vertical) Outside- and inside-mounted sash sensors: 1. For outside-mounted sensors: Measure the length of the mounting surface. 2. With the sash window fully closed, mark the location of the bottom of the sash window with the marker. 3. With the sash window fully open, mark the location of the bottom of the sash window with the marker. 4. Measure the length between the open and closed marks. Add 2 inches (5 cm) to account for over-travel. NOTE: For outside mounting: This measurement must not exceed the mounting surface length from Step 1. 5. Erase the marks on the fume hood by using isopropyl alcohol and a soft cloth. Cutting and Mounting the UniTrak (Vertical Only) WARNING: Do not cut horizontal sensors. Operation of the second actuator car will be lost. 1. Compare the actual length of the sensor strip with the required length of the sensor strip determined in Measuring the Sash Opening. If necessary, use the trim tool kit to cut the sensor strip. Be sure that the sensor is face up. See Figure 2. If you do not have to cut the sensor strip, skip to Step 3. 2. Separate the two sensor wires and seal the cut ends with the provided silicon (small, unmarked white tube). See Figure 2. Siemens Building Technologies, Inc. Page 3 of 13 Document No. 546-00449 Installation Instructions August 10, 2004 ACTUATOR LENGTH OF SENSOR TRIM LINE CUT UNITRAK SENSOR SILICON SEALANT SEAL END OF SENSOR WITH THE SILICON INCLUDED IN THE SMALL WHITE TUBE. FUM0337R1 Figure 2. Cutting UniTrak Sensor Using the Trim Tool Kit. 3. Use the alcohol towelette to clean the surface on which the UniTrak sensor is to be applied. Dry the surface thoroughly before mounting the UniTrak. 4. Remove the protective backing from the sensor strip. Make sure the sensor connector is positioned at the top of the sensor. 5. Be certain that there is a gap of least 3/8-inch between the sensor strip and the sash panel. 6. When attaching the UniTrak to the mounting surface, hold one end up and lightly place the opposite end down. The UniTrak should be mounted as straight (parallel to the sash) as possible. NOTE: If applied without pressure to the mounting surface, you may remove and reapply the UniTrak if necessary. If pressure is applied, the adhesive is permanent. 7. Locate the correct mounting area for the UniTrak sensor. See Figure 3 and Figure 4. 8. Slide the actuator block to the bottom of the UniTrak sensor strip. Figure 3. Outside Installation of UniTrak Sensor. Figure 4. Inside Installation of UniTrak Sensor. Page 4 of 13 Siemens Building Technologies, Inc. Document No. 546-00449 Installation Instructions August 10, 2004 Mounting the UniTrak (Horizontal) 1. Remove the fume hood front access panel. If the fume hood does not have an access panel, remove the top front airfoil to make installing the UniTrak sensor easier (Figure 5). Figure 5. Removal of Front Access Panel. 2. Locate the correct mounting area for the UniTrak sensor. See Figure 6, Figure 7, and Figure 8. Figure 6. UniTrak Mounting for Kewaunee Visionaire and Kewaunee Airflow Supreme (Combination-Style Fume Hoods). Figure 7. UniTrak Mounting for Hamilton Safeair (Combination-Style Fume Hood). Figure 8. UniTrak Mounting (Horizontal-Style Fume Hood). Siemens Building Technologies, Inc. Page 5 of 13 Document No. 546-00449 Installation Instructions August 10, 2004 3. Use the alcohol towelette to clean the surface on which the UniTrak is to be applied. Dry the surface thoroughly before mounting the UniTrak. 4. Measure and mark with the pencil the midpoint of the fume-hood mounting surface. Measure and mark with the pencil the midpoint of the UniTrak sensor. 5. Remove the protective backing from the UniTrak sensor. 6. Align the two marks made in Step 4. When attaching the UniTrak to the mounting surface hold one end up and lightly place the opposite end down. The UniTrak must be mounted as straight as possible. NOTE: If applied without pressure to the mounting surface, you may remove and reapply the UniTrak if necessary. If pressure is applied, the adhesive is permanent. Bending Linkage (Vertical) NOTE: Bends will reduce overall length by 1/2 inch to 1-1/2 inches. Outside sash UniTrak mount 1. Estimate the mounting position of the linkage (approximately 1 inch from the edge of the sash) (Figure 9). FUM0346R1 Figure 9. Location of Vertical Linkage. FUM0217R2 SASH HANDLE X ACTUATOR BLOCK UNITRAK VERTICAL SASH LINKAGE FUM0359R1 Figure 10. Measuring Between Sash and UniTrak Sensor. 2. Measure the distance from the edge of the sash frame to the far edge of the actuator block = X (Figure 10). 3. Add 1-1/2 inches to X. 4. Using the 1-1/2 inches + X value, measure from the outer edge of the mounting plate and mark this location (Figure 11). (X+1 1/2") MARK LINKAGE AND BEND HERE Figure 11. Marking First Linkage Bend. Page 6 of 13 Siemens Building Technologies, Inc. Document No. 546-00449 Installation Instructions August 10, 2004 5. For sensors mounted at a 45-degree angle, using the linkage-forming tool, bend the linkage at a 45-degree angle on the mark so the linkage is parallel to the sash (Figure 12). FUME HOOD SASH LINKAGE ACTUATOR FUME HOOD OUTSIDE WALL FUM0343R1 Figure 12. Linkage on 45 Angle. FUME HOOD SASH LINKAGE ACTUATOR FUME HOOD OUTSIDE WALL FUM0360R1 6. For sensors mounted at a 90-degree angle, bend the linkage at a 90 ° angle on the mark so the linkage is parallel to the sash (Figure 13). Figure 13. Linkage on a 90 Angle. 7. Clear any obstacles between the sash and the actuator with additional linkage bends. 8. Place linkage against the sash; mark an approximate location to trim the excess linkage. NOTE: When trimming off excess linkage, make sure there is enough of a fork to fit through the actuator. See Figure 14 and Figure 15. 9. Using the linkage-forming tool, cut or score location that will be broken off (Figure 14). Bend the linkage back and forth until it breaks. FUM0351R1 Figure 14. Cutting the linkage. 10. Clean the mounting area with an alcohol towelette and allow drying. 11. Attach the linkage to the actuator car by inserting it through the holes on the side of the actuator car (Figure 15). UNITRAK LINKAGE ACTUATOR BLOCK FUM0361R1 Figure 15. Attaching Linkage to Actuator Block. 12. Remove the protective paper from the adhesive backing on the mounting plate. 13. Close the sash; move the actuator and linkage to your estimated mounting position. 14. Lightly press the mounting plate onto the sash. NOTE: Make sure that the plate is mounted so that the sash can travel without running the actuator block off the track or interfering with any obstacles. 15. Adjust the mounting plate if necessary and firmly attach the mounting plate to the sash. Siemens Building Technologies, Inc. Page 7 of 13 Document No. 546-00449 Installation Instructions August 10, 2004 Bending Linkages (Horizontal) NOTE: If more than one UniTrak is mounted on the fume hood, repeat the following steps for each UniTrak. Bends will reduce overall length by 1/2 inch to 1-1/2 inches. A 45-degree angle will clear most obstacles. 1. Estimate the mounting position of the linkage (approximately 1 inch from the top edge of the sash) (Figure 16). FUM0345R1 HORIZONTAL SASH LINKAGE FUM0358R1 REMEMBER TO CLOSE THE SASH Figure 16. Location of Horizontal Linkage. 2. Using the permanent marker, mark the linkage where it is even with the UniTrak actuator car. 3. Measure the distance from the edge of the sash frame to the far edge of the actuator car = X (Figure 17 and Figure 18). Figure 17. Linkage Clearance Measurement. Figure 18. Linkage Clearance Measurement for Dual UniTrak sensors. (X+1/8") MARK LINKAGE AND BEND HERE FIRST ACTUATOR BLOCK MARK Figure 19. Marking the First Linkage Bend. 4. Add 1/8 inch to X. 5. Using the 1/8 inch + X value, measure from the first actuator car mark toward the mounting plate, mark this location (Figure 19). Page 8 of 13 Siemens Building Technologies, Inc. Document No. 546-00449 Installation Instructions August 10, 2004 6. Using the linkage-forming tool, bend the linkage at a 45-degree angle on the second mark so the linkage is parallel to the sash (Figure 20). REMEMBER T O CLOSE THE SASH FIRST LINKAGE BEND FUM0363R1 Figure 20. First Linkage Bend. 7. Bend 2—Bend the linkage down toward the sashes at a 45-degree angle 1/2 inch from Bend 1. (Figure 21). FUM0364R1 REMEMBER T O CLOSE THE SASH Figure 21. Second Linkage Bend. 8. Final Linkage Bend—Place linkage against sash, mark where the linkage aligns with the actuator (Figure 22). Figure 22. Marking the Final Linkage Bend. 9. Bend linkage toward sash at 90-degree angle (Figure 23). 10. Clear any obstacles between the sash and the actuator with additional linkage bends. Figure 23. Completed Horizontal Linkage. 11. Use the completed linkage to mark the three required bends on another unbent linkage. Bend the new linkage so that it is identical to the first. 12. Repeat Steps 1 through 11 for the second UniTrak. Siemens Building Technologies, Inc. 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