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Gelco Nordic ApSHylkedamvej 70 : DK-5591 Gelsted

Tel.: 45 63 46 54 08 : Fax: +45 6346 5404

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Gda_skversion 2.3.0.ENG-2008-01-29

TECHNICAL AND OPERATIONALDOCUMENTATION

Natural smoke & heat exhaust ventilators with/without daily ventilation,ventilation hatches, fixed skylights and roof access hatchways

MCR – PROLIGHTC, E, NG type

MCR PROLIGHT of C type SMOKE VENT

MCR PROLIGHT of E type VENTILATION HATCH

MCR PROLIGHT of NG type SKYLIGHT

ACCESS HATCHWAY

HATCHES MCR PROLIGHT OF C, E, NG TYPE

TECHNICAL AND OPERATIONAL DOCUMENTATION

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CONTENTS

1. INTRODUCTION........................................................................................................................................ 3

2. PURPOSE OF THE DEVICE..................................................................................................................... 3

3. CONSTRUCTION AND PRINCIPLE OF OPERATION OF THE DEVICE.............................................. 3

4. TRANSPORT AND DELIVERY............................................................................................. .................... 5

5. ASSEMBLY OF THE DEVICE................................................................................................................... 5

6. METHODS OF MOUNTING AND ROOF WORK FOR HATCHES ......................................................... 9

7. DEFLECTORS AND DIRECTING NOZZLES......................................................................................... 10

8. HATCH LEAF ADJUSTMENT ............................................................................................................... .. 11

9. CONTROL ................................................................................................................................................ 109.1. Pneumatic control ................................................................................................................................................................11

9.2. Electrical control...................................................................................................................................................................13

9.3. Ventilation function...............................................................................................................................................................14

10. LEAF FILLING........................................................................................................................................ 15

11. MAINTENANCE OF HATCHES, ACCESS HATCHWAYS AND SKYLIGHTS................................... 16

12. TERMS OF GUARANTEE AND SERVICE........................................................................................... 17



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1. INTRODUCTIONThe aim of this technical and operational documentation (DTR) is to acquaint the user with purpose,construction, principle of operation, correct assembly and operation of the smoke and ventilationhatches, access hatchways and skylights MCR-Prolight. The DTR contains also additional informationon operating conditions, maintenance, and terms of guarantee of the product.The present technical and operational documentation concerns the hatches, skylights and accesshatchways MCR-Prolight of C, E and NG type. The hatches MCR-Prolight of DVP type are describedin another DTR.Observing the recommendations contained in the technical and operational documentation shallensure correct functioning of the systems in the scope of smoke exhaust and/or venting, as well assafety of the system users.

2. PURPOSE OF THE DEVICESmoke hatches MCR-Prolight are automatic smoke exhaust devices. The basic function of smokeexhaust hatches MCR-Prolight is to exhaust smoke, combustion gases and heat energy fromenclosed spaces (production floors, storage spaces, public facilities, etc.) to the outside of buildings, inorder to protect human lives and property by:

• maintaining escape routes with low smoke levels,• facilitating fire-fighting action by creating a low layer with low smoke levels,• providing protection for the building structure and outfit,• limiting fire damage caused by smoke, hot combustion gases and thermal decomposition

products.Smoke hatches may also serve the function of ventilation hatches, smoke exhaust and ventilationhatches, access hatchways, or roof lighting.By using smoke exhaust hatches, the investor gains the opportunity to:

• reduce the fire resistance class of the building,• enlarge the acceptable fire zones,• lengthen the escape routes.

Smoke hatches MCR-Prolight are a part of the smoke control system which includes other products ofMERCOR SA, e.g.: smoke exhaust hatches in continuous rooflights and skylights MCR-Prolight,smoke curtains MCR-Prosmoke, central controllers MCR9705 and MCR0204 and others.

3. CONSTRUCTION AND PRINCIPLE OF OPERATION OFTHE DEVICEDepending on the requirements of individual customers, MERCOR offers smoke hatches, skylightsand access hatchways MCR PROLIGHT PLUS on plain and skew bases, in a wide range of openingdimensions and base heights. All steel elements are protected with a zinc coating applied by hot-galvanising or electro-galvanising.As standard, the bases are delivered with 20 mm thick thermal insulation. Individual selection of thethickness and type of thermal insulation is possible.The following filling types of openable leafs and skylights are used:

• cellular polycarbonate, 10 to 25 mm thick, different degrees of transparency, different heattransfer coefficients,

• single, double, and triple acrylic domes,• solid polycarbonate boards,• laminar boards (e.g. aluminium – thermal insulation – aluminium) – so called “blind” filling.



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Hatches MCR-Prolight of C, E and NG type are offered with the following control systems:• electrical control,• pneumatic control,• pneumatic-electrical control,• mechanical control.

Tripping of smoke exhaust hatches or smoke exhaust and ventilation hatches may be realised bothmanually from the user level and automatically by thermal fuses, MCR type central smoke exhaustcontrollers, or fire alarm signalling controllers.

Smoke vents, smoke exhaust and ventilation hatches, ventilation hatches, and access accesshatchways MCR-Prolight consist of a fixed part – the base, and a movable part – the leafs with filling,while skylights consist only of a fixed part – the base with filling.

Fig. 1. Hatch MCR Prolight

a/ C, E type

b/ NG type

1. filling2. pressing frame3. supporting frame4. leaf cross-bar5. actuators holder6. smoke exhaust actuator7. venting actuator (option)8. hook console9. base10. thermal insulation of the base11. leaf gasket12. base flange13. hinge14. external planking – galvanized

steel sheet

1. filling2. pressing frame3. supporting frame4. leaf cross-bar5. actuators holder6. smoke exhaust actuator7. venting actuator (option)8. hook console9. base10. thermal insulation of the base11. leaf gasket12. base flange13. hinge14. external planking – galvanized

steel sheet



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4. TRANSPORT AND DELIVERYSmoke vents MCR-Prolight of C, E, NG type are delivered in assembled form but in particular cases(additional external working, low bases, etc.) they may be delivered in the form of assemblies andsubassemblies. The following items are always delivered separately: deflectors, directing nozzles,domes. It is caused by the necessity to protect individual elements of hatches against damage duringtransport, and to ensure the safety of road traffic. Unloading should be performed under supervision ofa person authorised by the manufacturer, using generally available unloading means or manually.

Fig. 2. Transport using a crane (a) and using a forklift (b)

5. ASSEMBLY OF THE DEVICEHatches, access hatchways and skylights should be seated on structural elements of the roof, suchas: purlins, trimmer beams, structural sheet metal of the roof, reinforced concrete plinth.Smoke vents may be installed on roofs of steel, concrete, or wooden structure. The hatch base has aprotrusion (shelf) in the lower part, used for supporting and fixing the hatch to the supporting structure.Adequate fasteners (min diameter 6 mm) should be chosen, depending on the material of thesupporting structure (steel, concrete, wood). Fasteners should be installed at a span of max 50-60 cm.

Fig. 3. Method of seating the hatches on the roof

Hatch bases are adapted for roof work using roofing paper, PVC membrane, or sheet metal. Theupper part of a hatch base is equipped with a strip of galvanised steel sheet on the entire perimeter,for mechanical fixing of roofing or roof work elements using screws. In the case if the roof is coveredwith a membrane, it is possible to use a strip of PVC-coated metal sheet (option) for easier assembly.

ATTENTION: if bituminous roofing paper is heated to external planking (sheet metal strip) it isOBLIGATORY to use protection against heat for smoke vent leaf’s fillings and spacers.

Struts

leaf filling

pressing frame AL

leaf frame

hatch base

fastening screw

supporting structuresteel section

leaf filling

pressing frame AL

leaf frame

hatch base

expansion bolt

supporting structurereinforced concrete plinth

leaf filling

pressing frame AL

leaf frame

hatch base

wood screw

supporting structurewooden



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6. METHODS OF MOUNTING AND ROOF WORK FORHATCHESFig. 4. Steel base on reinforced concrete slab –finishing with membrane

Fig. 5. Steel base on reinforced concrete slab –finishing with roofing paper

1. steel base of the hatch or skylight2. sheet metal strip for membrane mounting3. thermal insulation of the base4. finishing with membrane5. thermal insulation of the roof6. reinforced concrete slab

1. steel base of the hatch or skylight2. sheet metal strip for roofing paper mounting3. thermal insulation of the base4. finishing with roofing paper5. thermal insulation of the roof6. reinforced concrete slab

Fig. 6. Steel base on steel structure – finishing withmembrane

Fig. 7. Steel base on steel structure – finishing withroofing paper

1. steel base of the hatch or skylight2. sheet metal strip for membrane mounting3. thermal insulation of the base4. finishing with membrane5. thermal insulation of the roof6. trapezium sheet metal7. additional roof work8. steel supporting structure

1. steel base of the hatch or skylight2. sheet metal strip for roofing paper mounting3. thermal insulation of the base4. finishing with roofing paper5. thermal insulation of the roof6. trapezium sheet metal7. additional roof work8. steel supporting structure



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1. steel base of the hatch or skylight2. sheet metal strip for membrane mounting3. thermal insulation of the base4. finishing with membrane5. thermal insulation of the roof6. trapezium sheet metal7. steel supporting structure

1. steel base of the hatch or skylight2. sheet metal strip for roofing paper mounting3. thermal insulation of the base4. finishing with roofing paper5. thermal insulation of the roof6. trapezium sheet metal7. steel supporting structure



1. steel base of the hatch or skylight2. sheet metal strip for membrane mounting3. thermal insulation of the base4. finishing with membrane5. thermal insulation of the roof6. trapezium sheet metal7. steel supporting structure

1. steel base of the hatch or skylight2. sheet metal strip for roofing paper mounting3. thermal insulation of the base4. finishing with roofing paper5. thermal insulation of the roof6. trapezium sheet metal7. steel supporting structure



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Fig. 12. Skew steel base on steel structure Fig. 13. Skew polyester base on steel structure

1. steel base of the hatch or skylight2. sheet metal strip for roofing paper or

membrane mounting3. thermal insulation of the base4. finishing with membrane5. thermal insulation of the roof6. trapezium sheet metal7. steel supporting structure

1. polyester base of the hatch or skylight2. thermal insulation of the base3. finishing with roofing paper or membrane4. thermal insulation of the roof5. trapezium sheet metal6. steel supporting structure

Fig. 14. Steel base on steel, wooden, or reinforcedconcrete plinth

1. steel base of the hatch or skylight2. thermal insulation of the base3. thermal insulation of the overlay4. eaves5. finishing with roofing paper or membrane6. thermal insulation of the roof7. reinforced concrete slab



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7. DEFLECTORS AND DIRECTING NOZZLES1. Deflectors are used for increasing the active surface area of smoke exhaust of the smoke hatches.

Deflectors are made of galvanised steel sheet, or optionally of aluminium or polyester sheet, andmay be painted in any colour of RAL palette. They are mounted using a set of screws and nuts,through holes prepared in the hatch base.

2. Directing nozzle is used for increasing the active surface area of smoke exhaust and it is mountedunder the hatch. It is made of galvanised steel sheet, or optionally of aluminium sheet orfibreglass-reinforced polyester, and may be painted in any colour of RAL palette. The nozzleshould be mounted using metal fasteners chosen depending on the material of the supportingstructure (min diameter 5 mm), at a span of max 50-60 cm, through the upper flange of the nozzle(Fig. 15 and 16).

1. Deflector with consoles2. Mounting screws (cap screws)3. Hatch base

Fig. 15. Mounting of deflector to hatch base

Fig. 16. Directing nozzle

a, b – nominal dimensions of the hatch



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Fig. 17. Suspending a directing nozzle under ahatch on steel structure

Fig. 18. Suspending a directing nozzle under a hatchon concrete plinth

8. VENT LEAF ADJUSTMENT(HOOK CONSOLE, EKE BOLTS AND 'T' BOLTS)

The hatch leaf is connected to the actuator with a hook console. The hook console is locked on a Tbolt. Pneumatic and electrical spindle actuators are connected to the hook console with an eye boltthat is screwed into the piston rod/spindle of the actuator. Play of the hatch leaf should be reduced byscrewing in the eye bolt or by adjusting the T bolt. The eye bolt or the T bolt should be protectedagainst screwing out with a locknut. In the case if an additional 230 V~ electrical actuator is used forventilation in a system with pneumatic actuator, the T bolt is screwed into the toothed strip or thespindle of the 230 V~ electrical actuator.

Fig. 19. T bolt Fig. 20. Hook console Fig. 21. Eye bolt

1. steel base of the hatch or skylight2. sheet metal strip for mounting of

the roofing board or membrane3. thermal insulation of the base4. finishing with roofing paper or

membrane5. thermal insulation of the roof6. trapezium sheet metal7. additional roof work8. steel supporting structure9. directing nozzle

1. steel base of the hatch or skylight2. sheet metal strip for mounting of

the roofing board or membrane3. thermal insulation of the base4. finishing with roofing paper or

membrane5. thermal insulation of the roof6. steel supporting structure7. directing nozzle



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Fig. 22. Connection of actuators with hook console

9. CONTROLOperation of the smoke exhaust hatches, smoke exhaust and ventilation hatches, and ventilationhatches MCR-Prolight of C, E, NG type requires some devices for their opening and closing. Thesedevices form a control system for smoke exhaust or smoke exhaust and ventilation. Depending on thetype of devices used, a smoke exhaust control system may be executed as:

• pneumatic system,• electrical system,• mechanical system,• pneumatic-electrical system (pneumatic part for smoke exhaust and electrical part controlling

the ventilation).Depending on the method of control, the hatches MCR-Prolight of C, E, NG type are equipped withpneumatic actuators with thermal trippers, electrical actuators or gas springs (for smoke exhaustcontrol), and additionally with pneumatic and electrical actuators for natural ventilation control.Hatchways are equipped with a gas spring to assist opening.

9.1. Pneumatic controlDepending on the system configuration, it may be necessary to connect additional pneumatic conduitsto the hatch (e.g. copper/steel tube to an emergency box with cartridges).



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Fig. 23. Method of mounting the flexible conduits of the pneumatic system

Fig. 24. Connection of the hose joint with the copper/steel tube

Threaded connections of hose joints with valves, actuators, etc. are sealed using suitable chemicalagents, e.g. Loctite 243 (recommended) or Teflon tape, by winding it on the thread. Loctite 243 shouldbe applied in several (2-3) drops on the thread for sealing. After making the screwed connection,Loctite 243 sets, sealing the connection and protecting it against uncontrolled loosening (important inthe case of actuator connections). Such protected hose joint may only be unscrewed using hand tools.

Smoke vents with pneumatic actuators are equipped with a cord that is limiting mobility of thesmoke vent’s leaf. Cords must be unlocked before launch of the smoke vent [cords must hangdown freely]

Nut

Conduit

Clamping ring

Bush (for plasticconduits)

Body

Copper tube

Clamping ring

Body

Nut



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NOTE: For safety reasons during transport, the thermal tripper in the hatch is not armed. Afterthe hatch is mounted together with roof work, possible plays of the hatch leaf should bereduced and the thermal tripper should be armed.Arming of the thermal tripper:

- check if the screw tightening the needle spring (1) is unscrewed, and if not, fully unscrew itmanually,

- install the alcohol ampoule (2) in the gas flow controller socket, with the sharpened endtowards the body, and manually tighten the screw fastening the ampoule,

- slide in the valve slider (4),- fully tighten the needle spring using the screw (1) – manually,- check if the cartridge needle is hidden, and if the gasket is present in the cartridge socket,- manually screw in the CO2 cartridge (3).

Fig. 25. Pneumatic actuator – lock releasing direction Fig. 26. Thermal tripper

Pneumatic actuators for smoke exhaust have an internal lock that prevents the closing of a fullyopened hatch leaf. Method of closing the hatch leaves after emergency opening for systems withoutthe remote closing function:

1. Release CO2 from the system by unscrewing the cartridge from the thermal tripper or theemergency box (note: the system is under high pressure – unscrew slowly, note: the cartridgemay freeze).

2. Release the locks of the actuator (5), by lifting them in the direction of the operating movementof the actuator (in accordance with the arrow in Fig. 25).

3. Lower the hatch leaf.4. Check the condition of the leaf lock.5. Insert a new CO2 cartridge into the thermal tripper or the emergency box.6. Possibly replace the thermal fuse (alcohol ampoule (2)).

9.2. Electrical controlThe leaf opening control system using a 24V= electrical actuator for smoke exhaust is delivered pre-mounted in the hatch. Adaptation for operation consists in connecting the eye bolt of the electricalactuator with the bolt of the hook console, and adequate adjustment so that the console reliably lockson the catch, while the electrical actuator is switched off after closing the hatch by the limit switch andnot by the overload switch.



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Method of connecting the MCR-W actuator (conductor polarisation):brown conductor +

blue conductor – } spindle moving in brown conductor –blue conductor + } spindle moving out

For control and power supply of electrical actuators MCR-W for smoke vents MCR PROLIGHTshould be used control units MCR9705 or MCR0204 and extension modules MCRR0424 and /orMCRR0448.

9.3. Ventilation functionThe ventilation functions may be realised using 2 basic methods:

- using pneumatic actuators with adequate system,- using an additional electrical actuator supplied with 230 V~ (figure below).

The electrical actuator for ventilation is usually not factory-mounted due to transport considerations. Itshould be mounted in the console of the opening system, using screws ST 12 1/8 (for the Exxx-230actuator) or threaded bolts (JMB actuators) delivered with the actuator. The actuator is equipped witha T bolt that is used interchangeably with the eye bolt connecting to the hook console.A weather monitoring station, e.g. MCRP054, is recommended in the ventilation control system, toclose the opened hatches in the case of a strong wind or rain, in order to protect the user property andthe hatch structure against damage.

Fig. 27. Actuator for ventilation control(Exxx-230 type)

Fig. 28. T bolt Fig. 29. ST 12 1/8 screw

Fig. 30. Connection diagram for 230 VAC electrical actuator for ventilationa/Actuator of type E xxx - 230 V has two circuits:• operating – movement direction control (conductors: black/brown – blue),• signalling (conductors: 2 x white; signalling of actuator opening – volt-free contact).

blac

k

brow

n

blue

whi

te

whi

te



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10. LEAF FILLINGFilling in the form of domes is delivered separately due to transport considerations. Domes should bemounted in the hatch leaf on the construction site, after mounting the hatch, according to the followingscheme:

1. remove the pressing frame (unscrew the M6x30 screws, remove the spacing sleeves);2. check the condition of the PES gasket on the supporting frame (clean from dust);3. lay the elements of multi-layer domes successively from the lowest to the highest – separate

individual domes with the delivered gasket – glue the gasket to the previously laid dome – onthe perimeter (see figure below) keeping 1 cm break at the corners;

4. place the pressing frame;5. insert the spacing sleeves;6. screw in the M6x30 screw, pressing the frame down simultaneously.

Cellular polycarbonate filling is delivered factory-mounted. Possible replacement consists inperforming the actions 1,2,4,5,6 according to the steps above.

Fig. 31. Mounted dome diagram

b/Actuator of type JMBB-500-300-LA has two circuits:• operating – movement direction control (conductors: brown/black1–blue),• signalling (conductors: black2/black3; signalling of actuator opening –volt-free contact).

brow

n

blac

k 1

blue

blac

k 2

blac

k 3

Pressing frame

M6x30 screw

Spacing sleeve

Supporting frame

External dome

Internal dome

Gasket

PES gasket



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11. MAINTENANCE OF HATCHESPeriodical maintenance and servicing inspections of installed devices are necessary during operation.Servicing and maintenance activities are performed by the authorised service MERCOR SA. Theinterval between servicing inspections is 6 months. The following actions performed by the user arerecommended between the inspections:

1. Checking the condition of electrical connections with special attention to mechanical damage.2. Checking the condition of pneumatic connections with special attention to mechanical

damage.3. Checking the condition of hook consoles (whether they are fully closed and not locked).4. Checking the condition of gaskets.5. Periodical cleaning of the surfaces of domes/polycarbonate boards:

for cleaning use a sponge or soft cloth and lukewarm water with addition of mildcleaning agents commonly used in household. The boards must not be scrubbedusing brushes or sharp objects. Do not use abrasive agents, strongly alkaline agents,solvents, etc. In doubtful cases make a test of the cleaning agent on a sample or asmall surface.



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12. TERMS OF GUARANTEE AND SERVICE1. MERCOR SA grants 12-month guarantee for the sold devices, unless the „delivery contract” or the

„delivery and mounting contract” states otherwise.2. If faults resulting from hidden defects of devices should occur during the period of guarantee,

MERCOR SA assumes the obligation to rectify them within a period not longer than 21 days sincereporting.

3. In the case of faults resulting from improper utilisation of devices, or other causes independent ofMERCOR SA, the purchaser shall be charged with the costs of their rectification.

4. MERCOR SA reserves the right to extend the repair period in the case of repairs which arecomplex or require the purchase of non-standard subassemblies [elements] or spare parts.

5. In accordance with the generally accepted practice, the guarantee does not cover:• damage and failures of devices caused by improper utilisation, lack of maintenance or lack of

periodical inspections,• damage of devices resulting from causes independent of MERCOR SA, in particular by

random events in the form of downpour, flooding, hurricane, inundation, lightning stroke,overvoltages in electric mains, explosion, hail, aircraft fall, fire, avalanche, landslide, orsecondary damage resulting from the above causes. Downpour is considered as rainfall withefficiency ratio of at least 4, established by IMiGW. Hurricane is considered as wind withvelocity of at least 17.5 m/s,

• damage resulting from neglecting the obligation of immediate reporting of every observedfault,

• deterioration of the quality of layers resulting from natural aging processes (fading, oxidation),• faults resulting from the use of abrasives or aggressive cleaning agents,• parts subject to natural wear during use (e.g. gaskets), unless a manufacturing defect

occurred in them.6. Every fault subject to the guarantee should be reported immediately to MERCOR SA.7. The purchaser is obligated to proper utilisation and maintenance of the purchased devices,

performing periodical servicing inspections (at least 2 times per year) and recording of everyservicing inspection in a „building object book” in accordance with art. 64 of the Building Law.

8. Guarantee and warranty expire with immediate effect in the following cases:• if the purchaser or the user introduces structural modifications on their own without prior

agreement with MERCOR SA,• if maintenance or periodical servicing inspections have not been performed on time or have

been performed by a service that is not authorised by MERCOR SA or if devices have beenutilised incorrectly,

• any intervention of unauthorised persons – except for the activities included in the scope ofnormal utilisation of devices.

9. Matters not regulated by these terms of guarantee shall be governed by regulations of the CivilCode, and especially art. 577-581.

SERVICING INSPECTIONS:1. Devices should be subject to periodical servicing inspections every 6 months during the entire

period of their operation.2. The servicing inspections should be performed by companies having adequate authorisation of

MERCOR SA.3. On issues related to service please contact the Service Department, phone 058/ 341 42 45 ext.

127 or fax 058/ 341 39 85, Monday to Friday from 8 to 16.

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