GFA ELEKTROMAT SI Installation Instructions Manual

-en- Status: 26.03.2021

Wiesenstraße 81 D-40549 Düsseldorf www.gfa-elektromaten.de [email protected]

1 General safety information .............................................................................................. 4 Safe operation ......................................................................................................................... 4 2 Technical Data ................................................................................................................ 6 3 Integrated safety brake ................................................................................................... 7 4 Mechanical installation .................................................................................................... 8 5 Electrical installation ..................................................................................................... 13 6 Limit switch adjustment ................................................................................................. 14 7 Motor connection .......................................................................................................... 15 8 Alternative motor connection ......................................................................................... 15 9 Limit switch connection ................................................................................................. 16 10  Emergency manual operation (emergency hand crank) ................................................ 17 11  Completion of commissioning / testing .......................................................................... 19 12  Declaration of incorporation / Declaration of conformity ................................................. 22 �� Symbols Warning - Potential injury or danger to life! Warning - Danger to life from electric current! Note - Important information! ▶ Requirement - Required action! Schematic representations are based on product examples. Deviations from delivered products are possible.

Specified use The drive unit is intended for vertically moving doors that need to be secured against dropping. A safety brake is integrated into the gearbox. The drive unit must be mounted directly on the shaft of the door. The drive unit must be protected against moisture and aggressive environmental conditions (such as corrosive substances). The drive units are only suitable for indoor use. Appropriate protective measures must be taken for outdoor installation. The drive unit is not intended for hazardous areas. The values specified in the technical data of the drive unit must not be exceeded. The safe operation can only be ensured if used as specified. Target audience of these installation instructions These installation instructions are geared towards qualified persons trained in the handling of door systems. Expert knowledge, relevant skills and practical experience are what set apart qualified persons. They are capable of safely carrying out the tasks involving installation, maintenance and modernisation according to the instructions. Safe operation The safe operation of the product can only be ensured if it is used as specified. Follow the installation instructions. Observe all specifications, especially warnings, when installing the product in the overall system. GfA is not liable for damage resulting from non-observance of the installation instructions. The resulting overall system must be reassessed for its safety in accordance with applicable standards and directives (e.g. CE marking). These installation instructions refer only to a part of the overall system and are not sufficient as the sole instructions for the overall system. The installer of the system must prepare the instructions for the overall system. We recommend entering the danger area of the system only when the drive unit is at a standstill.

 Please read these instructions before using the product.  Keep these instructions handy.  Include these instructions when passing on the product to third parties. Warning - Danger from improper use of the product!  Do not let children operate the product unsupervised or use as a toy. Warning - Danger to life from incorrect installation! Work carried out improperly may result in death or severe injury from electrical current or falling parts.  Allow only competent people to carry out the work.  Disconnect all cables from the power supply.  Observe valid regulations and standards.  Use suitable tools.

Type SG 115F Output torque 1000 Nm Output speed 10 rpm Output shaft / hollow shaft 55,00 mm Locking torque moment 2800 Nm Safety brake (testhouse/approval number) 14-003305-PR01 Maximum output speed open / close for frequency inverter operation 18 / 18 rpm Supply voltage 3~ 400 V Operating current 6,50 A Operating frequency 50 Hz Power factor cos φ 0,50 Maximum movement per hour 12 h-1 Hand forces 349 N Class of protection IP 65 Limit switch range (maximum revolutions of output shaft / hollow shaft) 20 Braking torque spring-loaded brake 20 Nm Braking voltage 103-130 V DC Rectifier type EGR 230/103 Temperature range -10 / +40 (+60) °C 1) When using a temperature range of +40°...+60°C use half of maximum movements per hour.

A safety brake is integrated into the gearbox of this ELEKTROMATEN. The safety brake protects against the door dropping due to breakage or wear of the gear teeth. The safety brake works regardless of the mounting position, speed and rotating direction. It is maintenance-free. The specification of the locking torque and the approval number of the safety brake are available in the technical data of these instructions. Warning - Danger of the door dropping! If you need to apply more than the permissible force of 390N (according to DIN EN 12604/DIN EN 12453) to move the door by emergency manual operation, this indicates a stalling on the drive unit or door. Releasing the stalling may cause the door to drop.  Adopt a secure position.  For drive units with brake, the emergency manual operation must be carried out against the closed brake.

Prerequisites The permissible loads on walls, fastenings, mountings and transmission elements must not be exceeded, even for maximum holding torques or locking torques (▶ refer to technical data). Connection elements ▶ Self-locking connection elements with a minimum strength of 800 N/mm2 (8.8) must be used. ▶ Utilize the hole diameter to the full. ▶ Use adequately dimensioned washers for elongated holes. BAGAB00002_Z002 BAGAB00003_Z002 3 : 1 Permissible mounting positions

▶ Vertical installation is possible only when an additional torque mount is used (Ⓑ).

manufacturer must also be observed during installation. Warning - Potential injury or danger to life!  During installation, be sure to use a lifting device that has a sufficient load- carrying capacity. ▶ Thoroughly grease the door shaft. BAGAE03003_Z002 ▶ Mount the keys. BAGAE03004_Z001

Version Ⓐ: ▶ Tighten all connection elements (M16) to 175 Nm. Install all other connection elements according to the specifications of the door manufacturer. Version Ⓑ: ▶ Raise the pedestal bearing (①). Install the torque mount (②+③). Do not tighten yet.

Version Ⓑ: ▶ Tighten all connection elements (M16) to 175 Nm. Install all other connection elements according to the specifications of the door manufacturer.

Warning - Danger to life from electric current!  Switch the mains OFF and check that the cables are de-energised  Observe the applicable regulations and standards  Make a proper electrical connection  Use suitable tools Performing electrical installation Remove the cover. Insert the motor plug. Insert the limit switch plug. BAHAA03_Z001 BAHAC07_Z001 Completing the electrical installation Mount the cable entries and/or cable glands.

The adjustment of the final limit positions OPEN and CLOSE is described in the instructions for the door control panel.

G1 Rectifier EGR M1 Motor X13 Motor plug Y1 Spring applied brake 8 Alternative motor connection G1 Rectifier EGR M1 Motor X13 Motor plug Y1 Spring applied brake

F10 Thermal contact S10 Emergency manual operation X12 DES connection 1 Safety circuit 2 Channel B (RS485) 3 Ground 4 Channel A (RS485) 5 Safety circuit 6 Supply voltage

The emergency manual operation is designed for opening or closing the door without power supply. Its activation interrupts the control voltage. Electrical operation is no longer possible. Warning – Injuries due to incorrect operation or falling objects!  Switch off voltage.  Adopt a secure position.  For drive units with brake, the emergency manual operation must be carried out against the closed brake. Warning - Danger of the door dropping! If you need to apply more than the permissible force of 390N (according to DIN EN 12604/DIN EN 12453) to move the door by emergency manual operation, this indicates a stalling on the drive unit or door. Releasing the stalling may cause the door to drop.  Adopt a secure position  For drive units with brake, the emergency manual operation must be carried out against the closed brake. Caution – Damage to components!  Do not move the door beyond the final limit positions.

The drive unit could start up unexpectedly and injure people should a wrong emergency hand crank be used. A wrong crank will drop out of the mounting and injure people.  Only use a crank with the correct diameter. The diameter is indicated on the crank handle switch: 12 mm 10 mm BAUA000101_Z001 Plug in the crank and turn until it engages (①). Open or close by turning the crank (②). After use, the crank may be attached to the drive unit. ▶ Attach as illustrated.

Check the following components and after that, mount all covers. Gearbox Check drive unit for oil loss (a few drops are not critical). Protect output shaft permanently against corrosion. Safety brake in the gearbox The safety brake requires no maintenance or inspection. Warning – Danger of the door dropping In the case of a gearbox damage, the internal safety brake is triggered to prevent the door from dropping. The gearbox stalls. Releasing the stalling may cause the door to drop!  Block the door for pedestrians and vehicles.  Do not release the stalling. Do not use the emergency manual operation.  Secure the door against dropping. Please observe the specifications of the door manufacturer.  The drive unit needs replacement. Please observe the specifications of the door manufacturer. Mounting Check all mounting elements (consoles, torque brackets, screws, retaining rings etc.) for tightness and impeccable condition. Electric wiring Check connection cables and cables for damage or pinches. Check screw and plug connections for correct seating and electrical contact.

Function to be checked in a de-energised state. Carry out functional test only between final limit positions. Limit switches Check the final limit positions by opening and closing the door completely. The safety zone must not be reached. Brake Warning – Injury or danger to life possible!  Carry out brake test. Overrun depends on the door and its equipment. The manufacturer's specifications must be observed.  The brake release for doors without counter-balancing may only be used in the CLOSE final limit position. Warning – Injury or danger to life possible! Service life of the brake - replacement of the entire brake in the case of:  Operation with mains supply after 250,000 door cycles  Operation with frequency inverter after 1,000,000 door cycles Degree of protection IP65i must be used in environments that may change the friction coefficient of the brake pad (atmospheres with oil, solvents, cleaning agents, etc.).

Note!  Have the drive checked annually by a specialist.  Shorter inspection interval for frequently used doors.  Observe the applicable regulations and standards.

Declaration of incorporation within the meaning of Machinery Directive 2006/42/EC for partly completed machinery, Appendix II Part B Declaration of conformity within the meaning of EMC Directive 2014/30/EU within the meaning of RoHS Directive 2011/65/EU We, GfA ELEKTROMATEN GmbH & Co. KG declare under our sole responsibility that the following product complies with the above directives and is only intended for installation in a door system. Drive unit SI 100.10-55,00 Part no.: 10002536 10011 We undertake to transmit in response to a reasoned request by the appropriate regulatory authorities the special documents on the partly completed machinery. This product must only be put into operation when it has been determined that the complete machine/system in which it has been installed complies with the provisions of the above- mentioned directives. Authorised representative to compile the technical documents is the undersigned. Düsseldorf, 10.08.2018 Stephan Kleine CEO Signature The following requirements from Appendix I of the Machinery Directive 2006/42/EC are met: 1.1.2, 1.1.3, 1.1.5, 1.2.2, 1.2.3, 1.2.6, 1.3.2, 1.3.3, 1.3.9, 1.5.1, 1.5.2, 1.5.4, 1.5.6, 1.5.7, 1.5.8, 1.5.9, 1.5.10, 1.5.11, 1.5.13, 1.6.1, 1.6.2, 1.6.4, 1.7.2, 1.7.3, 1.7.4.3. Standards applied: EN 12453:2001 Industrial, commercial and garage doors and gates - Safety in use of power operated doors - Requirements EN 12604:2017 Industrial, commercial and garage doors and gates - Mechanical aspects - Requirements EN 60335-1:2012 Household and similar electrical appliances - Safety - Part 1: General requirements EN 61000-6-2:2005 Electromagnetic compatibility (EMC) Part 6-2 Generic standards – Immunity standard for industrial environments EN 61000-6-3:2007 Electromagnetic compatibility (EMC) Part 6-3 Generic standards – Emission standard for residential, commercial and light-industrial environments