Operating instructions

Chain drive - ELEKTROMATEN® KETKE 5.24 WS - Serie SG50TKE 9.24 WS - Serie SG50integrated Hold to run control T801with additional relay-contact

51172209 - a 02.2011

GfA-ELEKTROMATENAustralia Pty Ltd

P.O. Box 267Roseville 2069 NSW

Telephone: 02 9882 2782Facsimile: 02 9882 2783

Email: info@gfa-elektromaten.netWeb: www.gfa-elektromaten.net

AUS

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52210131

SAFETY DIRECTIONS .................................................................................................. 4

TECHNICAL DATA ........................................................................................................ 6

DIMENSIONS ................................................................................................................ 7

INSTALLATION INSTRUCTIONS .................................................................................... 8

EMERGENCY MANUAL OPERATION ........................................................................... 9

ELECTRICAL CONNECTION ........................................................................................ 11

Pass-door switch / slack-rope contact onto the shutter panel ........................................ 11

Safety control voltage circuit ........................................................................................ 11

Relay-contact .............................................................................................................. 11

Push button ................................................................................................................. 12

Hardware - overview .................................................................................................... 12

Relay-contact .............................................................................................................. 12

ADJUSTMENT .............................................................................................................. 13

Working limits OPEN / CLOSE.................................................................................... 13

Plunger P1: Hold to run OPEN / self hold CLOSE ........................................................ 13

ANNUAL INSPECTION .................................................................................................. 14

TRANSPORT / STORAGE / DISPOSAL ........................................................................ 15

DECLARATION OF INCORPORATION .......................................................................... 16

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OPERATING INSTRUCTIONS

GENERAL DIRECTIONSFor driving all rolling grilles, roller shutters and other horizontal or vertical movments. All otherapplications of the ELEKTROMATEN® need to be approved by the manufacturer.Where changes are made to the ELEKTROMATEN® (e.g. re-wiring), the manufacturer'sdeclaration of incorporation cease to apply.

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SAFETY DIRECTIONS

Safety Regulations

During the installation, initial operation, maintenance and testing of the ELEKTROMATEN®,it is necessary to observe the safety and accident-prevention regulations valid for the specificapplication.

In particular, you should observe the following regulations (this list is not exhaustive):European normative- EN 12453

Safety in use of power operated doors - Requirements- EN 12604

Industrial, commercial and garage doors and gates - Mechanical aspects -Requirements

Please check normative´s bellow.VDE-regulations- VDE 0100

Regulations regarding the construction of power installations with a nominalvoltage of up to 1000 V

- VDE 0105Operation of power installations

- EN 60204-1 / VDE 0113-1Safety of machinery - Electrical equipment of machines - Part 1:General requirements

- EN 60335-1 / VDE 0700-1Safety of household and similar electrical appliances - Part 1:General requirements

Basic DirectionsThis drive has been built and tested in accordance with EN 12453 Industrial, commercial andgarage doors and gates - Safety in use of power operated doors - Requirements and EN12604 Industrical, commercial and garage doors and gates - Mechanical aspects -Requirements and left the factory in perfect condition from the point of view of safety. To maintainthis condition and to ensure safe operation, the user must observe all the directions and warningscontained in these operating instructions.In principle, only trained electrical craftsmen should work on electrical equipment. They mustassess the work which has been assigned to them, identify potential danger sources andtake suitable safety precautions.Reconstruction of or changes to ELEKTROMATEN® are only permissible with the approvalof the manufacturer. Original replacement parts and accessories authorised by themanufacturer guarantee safety. Liability ceases to apply if other parts are used.The operational safety of an ELEKTROMATEN® is only guaranteed if it is used in accordancewith the regulations. The limiting values stated in the technical data should not be exceededunder any circumstances (see corresponding sections of the operating instructions).

Regulations− Please ensure that the local regulations relating to the Safety of Opera-

tions of Doors are followed

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SAFETY DIRECTIONS

Explanation of warningsThese operating instructions contain directions which are important for using the ELEKTRO-MATEN® appropriately and safely.

The individual directions have the following meaning:

DANGERThis indicates danger to the life and health of the user if the appropriateprecautions are not taken.

Please observe the safety and accident prevention regulations valid forthe specific application. The installation of the ELEKTROMATEN®, theopening of covers or lids and electrical connection must be carried outwhen the supply is switched off.

The ELEKTROMATEN® must be installed with the authorised coveringsand protective devices. Care should be taken that any seals are fittedcorrectly and screw couplings are tightened correctly.

In the case of ELEKTROMATEN® with a permanent mains connection, anall-pole main switch with appropriate back-up fuse must be provided.

Check live cables and conductors regularly for insulation faults orbreakages. When a fault is detected in the cabling, the defective cablingshould be replaced after immediately switching off the mains supply.

Before starting operation, check whether the permissible mains voltagerange of the devices corresponds to the local mains voltage.

Emergency stop devices in accordance with VDE 0113 should remainoperational in all operating modes of the control. Releasing the emergencystop device should not cause any uncontrolled or undefined restart.

The following warnings are to be understood as a general guideline for working with theELEKTROMATEN® in conjunction with other devices. These directions must be observedstrictly during installation and operation.

General warnings and safety precautions

CAUTIONThis warns that the ELEKTROMATEN® or other materials may be damaged ifthe appropriate precautions are not taken.

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TECHNICAL DATA

In the case of structurally similar ELEKTROMATEN® or special sizes, deviations are possible, inparticular in the output torque, output revolutions and the motor data. In each case, the details on thenameplate apply.

Regulations− Please ensure that the local regulations relating to the Safety of Opera-

tions of Doors are followed

Size TKE 5.24 WSSingle phase

TKE 9.24 WSSingle phase

Hollow shaft diameter mm 25,4 / 31,75 25,4 / 31,75

output torque Nm 50 90

static stability Nm 200 450

door weight up to approx.(observe permissible cable forces for balanceddoors with 1-2 counterbalancing springs on a drumof ø160 mm)

N 2000 4000

output revolutions min -1 24 24

motor performance kW 0,37 0,45

operational voltage V 1 x 240 1 x 240

frequency Hz 50 50

nominal motor current A 3,6 4,0

motor duty cycle ED S3 - 40% S3 - 20%

power supply / fusing on attachment side 3 x 1,52 / 10A 3 x 1,52 / 10A

limit switch range, max. revolutions of the hollow shaft 20 20

permissible temperature range(in the case of deviation, please check) -5°C / +40°C -5°C / +40°C

permanent sound emission dB(A) < 70 < 70

class of protection IP 65 65

ELEKTROMATEN® weight kg 15 17

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DIMENSIONS

- Subject to dimensional and structural changes- deviations in the overall length and the motor diameter are possible in special sizes

1 Hollow shaft / worm gear2 Electric motor3 Limit switch4 Emergency manual operation5 Interchangeable shaft

Model SK"Rapid hand chain operator"

max. Hand-forces ( N )

Size NHK SK

TKE 5.24 WSTKE 9.24 WS 63 167

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INSTALLATION INSTRUCTIONS

If the gearbox housing is provided with an ad-ditional coat of paint, the shaft sealing ringsshould not be painted under any circumstances.

General information for using a chain drive:−−−−− The sprocket is not allowed mounting out on the shaft (see drawing), it must be fixed as close

as possible to the gear.−−−−− The admissible chain - tension is not permitted to exceed.−−−−− It is essential to tighten the chain, and changing tightness is necessary with brackets

or slide rail.−−−−− At shafts and bearing housing the fracture-proof is dependent on the pull direction of chain.

Use with roller shutters etc.:−−−−− For insulated shutters with doublewalled, thick and / or deep sections, the rolling diameter

must be checked. Do not calculate using the tube diameter. The biggest torque momentwill be afterwards the 2 winding. Please request.

−−−−− In the selection chart by shutter weight it is additional calculated 20% for friction. Thisis calculated for normal using. If you have special requests please ask.

Use with vertical liftgates:−−−−− Please reduce the output torque with 20%.

The chain drive ELEKTROMAT® will bemounting with slide rails or console. Drivetakes place via a stub shaft with a sprocket (3).After removing the retaining ring and thesupporting disk (4), the stub shaft can be pulledout and the output side can be changed.The sprocket should only be assembled whenthe stub shaft is extended. The chain shouldnot be overstrained. (The sagging in the slackstrand should be maximum 2% of the axledistance); the sprockets should be in alignment.The standard transmission is 1:1. When thetransmission is changed to "high-speed" (largesprocket on the ELEKTROMATEN®), thepermissible leaf weight should be reduced(check with us, if necessary).

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Size TKE 9.24 WSTKE 5.24 WS

Art.-Nr. 30000567

B1 180

B2 135

B3 90

B4 25

L1 300

L2 270

L3 220

L4 11,5

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EMERGENCY MANUAL OPERATIONThe emergency manual operation is provided in order to open or close the door without anelectrical supply.

Warning! Danger of injury through improper operation!- Before using the emergency manual operation, the main switch should be

switched off.- The emergency manual operation should only be carried out when the motor

is stationary.- A secure position should be adopted to operate the equipment manually.- In the case of ELEKTROMATEN® with a spring-operated brake, the door

should be opened or closed with the brakes on.- For safety reasons, the brakes should only be lifted for inspection.- Precautions must be taken on the construction site to prevent the brake

from being lifted unintentionally.

The door should not be moved beyond the normal end positions by theemergency manual operation, since this will operate the safety limit switch.Electrical operation of the door is then no longer possible.

Emergency manual operation by the manual hand crank (NHK) (Fig. 1)

- The manual crank must be inserted into the manualswitch receptacle and is turned whilst pressinggently until it engages, on that way the control circuitwould be interrupted. It is no longer possible tooperate the door electrically.

- The door can be opened and closed by turning themanual crank

- After pulling out the manual crank, electricaloperation is once possible. Fig. 1: Emergency manual operation

by the manual hand crank

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Emergency manual operation"Rapid hand chain operator" (Fig. 1)

- The red handle of the engaging and disengagingmechanism is first pulled lightly until it stops (max.operating force 50N), the control circuit is nowinterrupted, it is no longer possible to operatethe door electrically.

- The door can be opened and closed by pullingthe chain (2).

- By lightly pulling the engaging and disengagingmechanism by the green handle until it stops (3)(max. operating force 50N), the control circuit isre-made and the door is electrically operational.

Variation of the hand chain length (Fig. 2)

- The hand chain can be opened at the connectionpoint and can be lengthened or shortened withconnecting links.

- The connecting links should be bent togethercarefully.

- When changing the chain length, care shouldbe taken that the chain is cross - assembled(Fig. 2).

EMERGENCY MANUAL OPERATION

Fig. 1: Emergency manual operation"Rapid hand chain operator"

Fig. 2: Variation of the handchain length

Execution: SK "Rapid hand chain operator" (Fig. 1)Execution: KNH "Chain operator" (without Fig.)

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If the cover is dismantled hold to run control and terminals are accessible.

AttentionThe drive is designed to be used only with doors that have a build -inmechanical end stops in the construction.

Warning! Danger to life through electric shockBefore starting assembly, disconnect the cables from the electricity supplyand check that they are dead.

Only trained electrical craftsmen should work on electrical equipment. They must assess thework which has been assigned to them, identify potential danger sources and take suitablesafety precautions.

The following tools are recommended for the appropriate electrical connection of theELEKTROMAT®:− Multimeter (for alternating current up to at least 750 VAC)− Electrically insulated screw driver− Cable stripper− Diagonal cutter− Piercing tool to open the cable ducts− Wire end ferrules with associated pinching tongs when using flexible cables

Pass-door switch / slack-rope contact onto the shutter panelIf fitted, the control T801 is able to evaluate pass-door and slake-rope contact with a 5Vsafety control voltage circuit. The 2-pole terminal X2 can be used to connect a preparedspiral cable.

Safety control voltage circuitThe terminals X1/ 21 - 24 are reserved only for safety control voltage circuit. An interruptionof the safety circuit causes the control current to be interrupted. Electrical operation is thenno longer possible.The terminals are connected to the safety switch of the emergency manual operation and/orthe thermal protection of the motor. If additional safety switches required the switches shallbe connected in-line with the existing switches and additional terminals.

Relay-contactThe relay-contact can be used as release signal for dock-levellers. The contact is activated infully open position of the door. No further adjustments have to be made.

ELECTRICAL CONNECTION

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24V AC/DC10-100mA

Relay-contact

Three push button Key switch withstop button

Key switch

OPEN

STOP

CLOSE STOP

OPEN /CLOSE

OPEN /CLOSE

or or

Push button

Hardware - overview Discription Print:C1 CapacitorF1 FuseF2 Replacement fuseF3 Thermal protectionM1 MotorP1 Plunger: Hold to run

OPEN / self hold OPENR1 RelayS3 Limit switch OPENS4 Limit switch CLOSES10 Emergency operator

X1 Mains supplyX2 Slack-rope switchX5 Three push button /

Key switch

X5 X5 X5

ELECTRICAL CONNECTION

X1 X5 X2P1F1

F2

R1

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ADJUSTMENT

The limit adjustment position determines the upper-and lower end position of the door.The limit adjustment is only possible if the ELEKTROMATEN® has an electrical supplyand a connected push button.

Fig. 1: Limit switch cam

AttentionCheck before setting the limits that the plunger is switched to the positionhold to run mode.(See fig. 2)

In order to adjust the limit switch for the upper stopping position of the door, the followingsteps should be carried out:

Upper stopping position- Rotate switching cam (1) of the S3 limit switch „OPEN“

to the middle of the switching cam (2) and tighten thecoarse adjustment screw with the hexagonal socketscrew key supplied.

- Close door, until limit switch switches again

- Open door again to final upper stopping position

- Correct upper stopping position, possibly by turning thefine adjustment screw (4)

Advice!The fine adjustment screw can be moved from both sideswith the hexagonal socket screw key

Lower stopping positionAfter closing the door the CLOSE limit switch S4 can be adjusted similarly to the upperstopping position.

Working limits OPEN / CLOSE

Plunger P1: Hold to run OPEN / self hold CLOSEWhen switching the plunger P1 self hold OPEN canbe adjusted. If an open impulse was given the doortravel to final OPEN position (1). Plunger positionsupplied is Hold to run position.

Plunger position on (2) = Self hold OPEN

Fig. 2: Plunger P1

P1

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ANNUAL INSPECTION

Directions for the inspector

Gearbox:The gear construction is maintenance-free and has lifetime lubrication. The output shaftshould be kept rust-free.

Attachments:All attachment screws should be inspected to make sure they are fitted securely and are inperfect condition.

Counter-balancing of sectional doors:According to the regulations regarding counterbalancing, the door should be balanced inevery position (cf. Installation instructions).

Brake (if fitted)The correct function of the brake should be checked during the annual inspection.Where there is increased wear, the brake lining or - once the rectifier has been disconnected- the entire brake can be exchanged.

The maintenance of power-assisted windows, doors and gates should onlybe carried out by persons authorized by the employer and who are familiarwith the respective maintenance work.

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TRANSPORT / STORAGE / DISPOSALThe ELEKTROMATEN® is assembled completely and is wired ready for connection.Transport and any storage should be carried out in the provided (or equivalent) packaging toavoid damage.On disposal the ELEKTROMATEN®,- metals- plastic parts- electric parts- lubricantsmust be separated.

SERVICE / REPLACEMENT PARTS / ACCESSORIESPlease note that replacement parts and accessories which have not been supplied by us havealso not been tested and released by us.Fitting and / or using such products can therefore negatively affect the above properties ofthe ELEKTROMATEN® and thus reduce its safety.

GfA accepts no liability for nor provides any guarantee against damage caused by usingnon-original replacement parts and accessories.

Faults which the users cannot rectify themselves should only be corrected by the manufacturerof the door equipment or another specialist firm. Replacement parts can also be requestedfrom such firms.

www.gfa-elektromaten.de

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Harmonised norms applied

EN 12453 Safety in use of power operated doors - Requirements

EN 12604 Industrial, commercial and garage doors and gates -Mechanical aspects- Requirements

EN 60335-1 Household and similar electrical appliances - Safety -Part 1: General requirements

EN 60204 Safety of machinery - Electrical equipment of machines -Part 1: General requirements

We, theGfA - Gesellschaft für Antriebstechnik

Wiesenstr. 81, 40549 Duesseldorf (Heerdt), Germanyhere by declare that the following product are conform with the

above EC guidelines and are only intended for installation in door equipment.

We are committed to submit the special documents with regard to the complete machine via ourdocumentation department to the market surveillance authorities on a reasoned request.

Authorised representative for the compilation of the relevant technical documents(internal EU address)

Dipl. Ing. Bernd Joachim SynowskyDocumentation representative

Incomplete machines within the meaning of the EC Directive 2006/42/EC shall only be intended tobe integrated into other machines or into other incomplete machines or systems or to be assembledtogether with such in order to form a machine within the sense of the Directive indicated above.Therefore, this product cannot be commissioned before it is determined that the entire machine/system to which it was integrated shall comply with the provisions of the Machinery Directiveindicated above.

chain drive - ELEKTROMAT®

DECLARATION OF INCORPORATIONfor partly completed machinery in terms of

Machinery Directive 2006/42/EG, Appendix II Part 1 B

GfA-Gesellschaft für AntriebstechnikDr.-Ing. Hammann GmbH & Co. KG

Wiesenstraße 8140549 Düsseldorf

Telefon: +49 (0) 211-500 90 0Telefax: +49 (0) 211-500 90 90

www.gfa-elektromaten.de

Düsseldorf, 29. 12. 2009 Stephan Kleine CEO Signature

Erstelldatum: 21.12.2009 Zeichnungs-Nr.: 52397051 Revisionsstand: a