Aperto X-Box 550 User manual

X-Box 550
X-Box 800
EN TRANSLATION OF THE ORIGINAL INSTALLATION AND OPERATING MANUAL
46725V001-422016-0-DRE-Rev.C_EN

Table of contents
2
Table of contents
General Information ...................................................... 3
Symbols ........................................................................................... 3
Safety instructions............................................................................ 3
Intended use .................................................................................... 3
Max. permissible door dimensions * ................................................ 4
Technical data (Aperto X-Box) ......................................................... 4
Scope of delivery.............................................................................. 5
General Installation....................................................... 7
Door types and accessories............................................................. 7
Overview of accessories (optional) .................................................. 7
Tools required................................................................................... 7
Personal protective equipment......................................................... 7
Installation...................................................................... 8
Safety instructions............................................................................ 8
Safety-related preparation of the door ............................................. 8
Lay the emergency release outside ................................................. 8
Installing slip door safety device ...................................................... 8
Tips for installation ........................................................................... 9
Selection of installation variants....................................................... 9
Preinstallation of installation variant A............................................ 10
Preinstallation of installation variant B ............................................11
Installation (example: installation variant B)................................... 12
Mounting and connecting the X-Box .............................................. 14
Connecting solar module ............................................................... 14
Commissioning............................................................ 15
Safety instructions.......................................................................... 15
Adjust door end positions for CLOSE + OPEN .............................. 15
Putting the battery units into operation........................................... 15
Programming the operator ............................................................. 16
Check door end positions OPEN + CLOSED ................................ 16
Checking the emergency release................................................... 16
Check the force settings................................................................. 16
Programming handheld transmitter................................................ 16
Mount the information sign............................................................. 17
Attaching the warning sign............................................................. 17
Operation/Use.............................................................. 18
Safety instructions.......................................................................... 18
Opening the door ........................................................................... 18
Closing door................................................................................... 18
Emergency release ........................................................................ 18
Control unit reset............................................................................ 18
Intermediate stop ........................................................................... 18
Safety stop 1 (power cut-off).......................................................... 18
Safety stop 2 (safety input) ............................................................ 18
Overload protection........................................................................ 18
LED signals on the control unit ...................................................... 19
Recharging battery unit.................................................................. 19
Setting the afterglow time of the LED lighting ................................ 19
Radio receiver................................................................................ 19
Programming handheld transmitter................................................ 19
Deleting a handheld transmitter button from the radio receiver ..... 20
Deleting a channel from the radio receiver .................................... 20
Deleting the radio receiver memory ............................................... 20
Extended functions and connections........................ 21
General information........................................................................ 21
Connection to the control unit ........................................................ 21
Opening control unit....................................................................... 21
Install and connect the additional button........................................ 21
Obstacle detection (DIP 1, 2 + 3)................................................... 22
Connect button 2 (DIP 2) ............................................................... 22
Connect warning light (DIP 4) ........................................................ 22
Backjump (DIP 6) ........................................................................... 23
Connecting photo eye .................................................................... 23
Pulse sequence of door movement (DIP7) .................................... 23
Carriage circuit board..................................................................... 23
Defined opening and closing (DIP 7) ............................................. 23
Partial opening (DIP 8)................................................................... 24
Maintenance and care................................................. 25
Safety instructions.......................................................................... 25
Cleaning chains and operator unit track......................................... 25
Changing the control unit fuses...................................................... 25
Replacing the battery unit fuse....................................................... 25
Maintenance and care................................................. 26
Regular testing............................................................................... 26
Miscellaneous.............................................................. 26
Disassembly................................................................................... 26
Disposal ......................................................................................... 26
Warranty and customer service ..................................................... 26
Troubleshooting .......................................................... 27
Further tips on troubleshooting ...................................................... 27
Service Hotline:
[phone]

3
Symbols
Warning signs:
Indicates imminent danger.
If it is not observed serious injuries may occur.
Important information symbol:
Information, useful advice!
Refers to a respective picture in the introduction or main text.
Safety instructions
General
These installation and operating manual must be read, understood
and complied with by persons who install, use or perform maintenance
on the operator.
Installation, connection and initial commissioning of the operator
may only be carried out by technically knowledgeable persons.
Only install the operator on correctly aligned and weight-balanced
doors. An improperly aligned door can cause serious injuries
or damage the operator.
The manufacturer assumes no liability for injuries, damage or break-
downs that occur due to non-compliance with the installation and
operating instructions.
Make sure that this installation and operating manual is kept within
easy reach in the garage.
Always ensure compliance with accident prevention regulations
and current standards in each respective country.
Observe and comply with the Employer’s Liability Rules
“Power-operated windows, doors and gates – BGR 232”.
(Applies to operators in Germany)
Always disconnect the plug for the control unit before working
on the operator.
Only use OEM (Original Equipment Manufacturer) spare parts,
accessories and mounting material.
If the operator is used only occasionally, the batteries should be
recharged after no later than two months in accordance
with regulations.
The service life of the battery may decrease at low temperatures
and as the battery gets older.
Storage
The APERTO X-Box must be stored in an enclosed, dry area at a room
temperature of –20 – +50 °C.
+50°
–20°
The operator should be stored horizontally.
+50°
–20°
Store the X-Box upright.
Operation
The operator may only be operated if a non-hazardous force value
has been set. This force value must be set low enough to ensure
that the closing force poses no risk of injury.
Never put your hand near the door when it is moving or near
moving parts.
Keep children, disabled persons and animals away from the door.
Do not drive through the door until it has been fully opened.
There is a risk of persons being crushed or cut by the mechanism
or sharp edges of the door.
If the garage does not have a separate entrance or the garage door
does not have a built-in slip door, you must install an emergency
release (release lock or Bowden cable) that can be operated from
outside.
Radio remote control
The remote control must only be used for devices and systems
in which radio interference will not endanger people, animals
or objects, or the risk is reduced by other safety devices.
The user must be made aware that systems that pose an accident
risk should only be remote controlled, if at all, if the user can actually
see the door.
The radio remote control may only be used if the door’s movement
can be watched and no persons or objects are within the range
of movement.
Keep the handheld transmitter so that an unintended operation
e.g., by children or animals, is prevented.
The user of the radio system is not protected from faults due to other
telecommunications equipment or devices (e.g. radio-controlled
systems that are licensed to operate in the same frequency range).
If substantial interference occurs, please contact your appropriate
telecommunications office which has radio interference measuring
equipment (radio location).
Do not operate handheld transmitters near locations or installations
that are sensitive to radio interference (e.g.: airports, hospitals).
Intended use
Caution! Irreparable damage to the operator!
Do not use the operator to open or close doors unless
the counterbalance is set (springs tensioned).
Otherwise, you will damage or destroy the motor
(transmission).
Caution! Risk of death!
Remove all cords, straps and locks necessary to operate
the door by hand.
The operator is intended exclusively to open and close doors.
Any other use does not constitute intended use.
The manufacturer accepts no liability resulting from use other than
intended use. The user bears the sole responsibility for any risk
involved. It also voids the warranty.
Doors automated with an operator must comply with the valid standards
and directives:
e.g. EN 12604, EN 12605.
The operator may only be used if it is in perfect working order and is
used as intended, in conscious observation of safety and hazards and
in accordance with the installation and operating instructions.
Malfunctions which could affect safety must be corrected immediately.
The door must be stable and torsionally stiff, i.e. it must not bend
or twist when being opened or closed.
The operator cannot compensate for any defects in the door
or incorrect installation of the door.
Only use the operator in a dry, non-hazardous area.
Do not install the operator in areas with a corrosive atmosphere
(e.g. salty air).
General Information

General Information
4
Max. permissible door dimensions *
APERTO X-Box:
Max. width: 550 800
– One piece door: 3500 5500 mm
– Sectional door: 3500 5500 mm
– Hinged double door **: – 2800 mm
– Side-sectional or roller door:
Track 2600 .................................................... 2350 2350 mm
Track 3000 .................................................... 2750 2750 mm
Track 3400 .................................................... 3150 3150 mm
– Up-and-over door | Canopy door: – 4500 mm
Approx. height
– One piece door:
Track 2600 .................................................... 2600 2600 mm
Track 3000 .................................................... 3000 3000 mm
Track 3400 .................................................... 3400 3400 mm
– Sectional door:
Track 2600 .................................................... 2350 2350 mm
Track 3000 .................................................... 2750 2750 mm
Track 3400 .................................................... 3150 3150 mm
– Hinged double door **: mm
Track 2600 .................................................... – 3000 mm
– Side-sectional or roller door:
Track 2600 .................................................... 2300 3000 mm
– Up-and-over door | Canopy door:
Track 2600 .................................................... – 1900 mm
Track 3000 .................................................... – 2300 mm
Track 3400 .................................................... – 2700 mm
Duty cycle: ........................................................ 15 15 %
* Door in accordance with EN 12604, EN 12605
** With standard hinged double door fitting, part no. 1501.
For taller doors, correspondingly longer tracks or track extensions
must be installed. Please ask you specialist dealer.
Technical data (Aperto X-Box)
General
Rated voltage: 24 V DC
Lighting: Integrated LED lighting
Operational temperature range: –10 °C to +45 °C
IP-code: IP 20
Working environmental emissions value: < 75 dBA – operator only
Operator: 550 800
Max. pulling and pushing force: 550 800 N
Rated pulling force: 150 240 N
Rated current consumption (approx.): 4.0 6.4 A
Rated power consumption: 110 160 W
Max. speed: 150 130 mm/s
Nominal power, standby (approx.): 0.1 0.1 W
Weight with track 2600: 16.0 16.0 kg
X-Box (battery and control unit):
Discharge voltage: 21 V
Charging end voltage
of the lead acid battery: approx. 28.8 V
Capacity: 14.4 Ah
Open-circuit voltage: 25.6–26.2 V
Self-discharge/Day: < 0.1 % of nominal capacity
Lifetime of the battery: At least 3–5 years
(Eurobat Standard)
Weigh of 3-piece X-Box: 16.2 kg
Weight of separate battery unit: 5.7 kg
APERTO operator 550
252
120
2600
3000 / 3400
375
30
max.22,5
max.
214
3240 /3640 /4040
35
176
245
115
APERTO operator 800
2600
3000 / 3400
375
30
max.22,5
max.
214
3240 /3640 /4040
35
176
125
270
137
252
X-Box
260 mm
110 mm
635 mm
745 mm
Package (L x W x H):
– Operator 790 x 160 x 160 mm
– Track 2600 1665 x 160 x 50 mm
– X-Box battery and control unit 765 x 335 x 180 mm

General Information
5
Scope of delivery
Check that the delivered parts are complete before beginning
installation! The actual scope of supply may vary depending
on the version.
4
2
5
10
12
7
62 4
3
2
1
8
9
11
13
Item Name Quantity
1. Carriage (chain guide) 1
2. C-track (uncoated) 2
3. Connecting sleeve (uncoated) 2
4. Guide idler “H” 1
5. Guide idler “V” 1
6. Chain in chain channel (chain channel is made
of plastic. It is not packaging. Do not remove!) 1
7. Push rod 1
8. Door bracket 1
9. Ceiling suspension unit | Ceiling suspension bracket |
Ceiling bracket | Ceiling attachment | Ceiling mount-
ing unit | Ceiling suspension fitting | Ceiling mount
1
10. Installation and operating manual 1
11. Installation bag 1
12. Slide-in part with control cable (length 5,000 mm) 1
13. Transmitter | Handheld transmitter | Hand-held
remote control | Hand-held sensor
1
16
15
14
17
15
Item Name Quantity
14. Control unit (with button and LED light field) 1
15. Battery units (left and right) 2
16. Support rail
(centre housing is already installed on the track)
1
17. Charger 1
Caution! Important information!
The Aperto X-Box must always be operated with both battery
units connected!
It is only possible to operate with only one battery unit when
both battery units are being recharged.
Caution! Important information!
Batteries must be recharged for 8–12 h every time.
This must be done regardless of what the charger display
shows, since some residual charging always occurs
by the charger in the last few hours.
Caution! Important information!
To increase the lifetime of the battery, the batteries must
be charged regularly once a month.
Caution! Important information!
Do not connect the solar module until both battery units
are pushed onto the centre station.
When removing both battery units, the solar module must
be separated from the centre station.
If this is not observed, damage to the electronics may occur.

General Information
6
EC Declaration of Conformity
for installation of an incomplete machine in accordance
with the Machinery Directive 2006/42/EC, Annex II, Part 1 A
APERTO Torantriebe GmbH
Hans-Böckler-Straße 29
73230 Kirchheim/Teck
Germany
hereby declares that the garage door operators
X-Box 550; X-Box 800
have been developed, designed and manufactured in conformity with the
• Machinery Directive 2006/42/EC
• Low Voltage Directive 2014/35/EU
• Electromagnetic Compatibility Directive 2014/30/EU
• RoHS Directive 2011/65/EU.
The following standards were applied:
• ESTI EN 300 202 V2.4.1
• ESTI EN 301 489-1 V1.9.2
• ESTI EN 301 489-3 V1.6.1
• DIN EN 60950-1: 2006 + A11:2009 +
A1:2010 + A12:2011 + AC: 2011 + A2:2013
• EN ISO 13849-1 12/2008, PL “C”Cat.2 Safety of machines – safety-related parts of controls
– Part 1: General design guidelines
• EN 600335-1 10/2012, where applicable Safety of electrical appliances/operators for gates
• EN 61000-6-3 11/2012 Electromagnetic compatibility (EMC) – interference
• EN 61000-6-2 06/2011 Electromagnetic compatibility (EMC) – interference resistance
• EN 60335-2-95 04/2011 General safety requirements for household and similar electrical appliances
– Part 2: Particular requirements for operators for vertically moving garage
doors for residential use
• EN 60335-2-103 06/2014 General safety requirements for household and similar electrical appliances
– Part 2: Special requirements for operators for gates, doors and windows
The following requirements of Annex 1 of the Machinery Directive 2006/42/EC are met:
1.1.2, 1.1.3, 1.1.5, 1.2.1, 1.2.2, 1.2.3, 1.2.4, 1.2.5, 1.2.6, 1.3.1, 1.3.2, 1.3.4, 1.3.7, 1.5.1, 1.5.4, 1.5.6, 1.5.14, 1.6.1,
1.6.2, 1.6.3, 1.7.1, 1.7.3, 1.7.4
The special technical documents have been prepared in accordance with Annex VII Part B and are submitted
electronically to the regulators on request.
The incomplete machine is intended for installation in a door system only to form a complete machine as defined
by the Machinery Directive 2006/42/EC. The door system may only be put into operation after it has been established
that the complete system complies with the regulations of the above EC Directive.
The undersigned is responsible for compilation of the technical documents.
Kirchheim, 20-04-2016
i.V.
Jochen Lude
Responsible for documents

General Installation
7
Door types and accessories
Accessories are not included in the scope of delivery.
D
A B
C
Door type Accessories
Swinging door |
One piece door • No accessories required
Sectional door
with single rail
• Sectional door fitting
with boomerang
• Release lock (19) *
Sectional door
with double rail
• Sectional door bracket
without boomerang
• Release lock (19) *
Rolling shutter door • Release lock (19) *
Up-and-over door |
Canopy door • Curved arm
Hinged double door • Caution! Contact specialist dealer!
• Special emergency release required
• Wing door fitting | Hinged double
door fitting
* Release lock for emergency release (19) is absolutely mandatory
if there is not a separate access point.
Slip door | Pass door | Built-in pass door
Caution!
If a slip door in set into the door, a slip door safety device (20)
must be installed. (Not included in the scope of delivery.)
Overview of accessories (optional)
21
19
18
20
Item Name
18. Bowden cable for extending the emergency release
19. Release lock for emergency release
20. Slip door safety device | Pass door fuse |
Slip door safeguard
21. Photo eye
• Telecody for wireless activation of the door with a number combination
• Code keypad for activation of the door with a number combination
• Key switch for activation of the door with a key
• Locking set
Tools required
Personal protective equipment
Safety glasses (for drilling)
Protective gloves (e.g. when handling cut-off pieces of perforated
strip steel)
A
B
C
D
General Installation

Installation
8
Safety instructions
Caution!
Walls and ceiling must be solid and stable.
Only install the operator on a correctly aligned door.
An incorrectly aligned door could cause serious injury.
The operator may be installed, connected and commissioned
by competent personnel only.
Do not move the door, if there are any people, animals or objects
in the area of movement.
Keep children, disabled persons and animals away from the door.
Wear safety glasses when drilling the fastening holes.
Cover the operator and track during drilling to prevent dirt from entering
the operator unit or operator track.
Use only approved fasteners (e.g. anchor fittings, screws).
The fasteners must be suitable to the material of the ceilings and walls.
The supplied track supply line must not be shortened.
Use only an original extension set to extend the line.
Live parts of the operator (voltage-carrying parts, e.g. C-track)
may not be connected to the ground or with live parts or grounding
conductors of other electrical circuits.
Safety-related preparation
of the door
Caution!
The preparations must be made with the utmost care,
since faulty preparations can lead to serious injuries
as well as major damage to the operator and your garage.
Caution! Risk of death!
Remove all cords, straps and locks necessary to operate
the door by hand.
Doors must be stable in themselves, since high traction and
compression forces are encountered. Reinforce lighter doors
made of plastic or aluminium if necessary before installation.
Ask a specialist retailer for advice.
All existing mechanical door locks must be removed or made
non-functional before beginning installation.
Check that the door runs smoothly.
The door must be counterbalanced.
Test: Half-open the door by hand. The door must remain in this
position. If the door moves up or down, re-adjust the door
mechanically. Ask a specialist retailer for advice.
Check the distance between the highest running point of the door (THP,
see Figure 11) and the lower edge of the C-track. The distance between
the THP and the lower edge of the C-track must be between 5 mm and
65 mm; the angle of the door arm must be max. 30° (see graphic 21).
If the distance is less than this, the operator must be moved back and
a longer push rod must be installed. Ask a specialist retailer for advice.
The travel path of the operator must be free of obstacles.
Obstacles must be properly removed before installation
since collisions are a safety risk and can damage the operator.
Adjusting the top roll of a sectional door
Lay the emergency release outside
Caution!
Most garages do not have a separate entrance (e.g. slip door).
That is why the emergency release on the operator must
be led outside to make it possible to open the door from
outside in the event of a power failure or door defects.
To do so, use the Bowden cable (18) or a release lock (19),
which is not included in delivery.
(See accessory instructions for installation)
Installing slip door safety device
Caution!
If a slip door is in set into the door, but not a slip door safety
device, a slip door safety device (20) must be installed.
(See accessory instructions for installation).
Installation

Installation
9
Tips for installation
• Check the delivery scope components before beginning installation;
this way you save time and unnecessary effort if a part is missing.
• It is safest and quickest to do installation with two people.
• If the operator cannot be installed in the centre of the door, it may be
shifted. Make sure that the door does not bow and get stuck in the rails.
Check:
Open and close the door by hand several times at the location where
the operator is to be installed. If the door can be operated easily at this
location (without exceeding the specified forces), then the operator can
be installed.
• Swing doors:
Because the mechanical locking of a door equipped with a operator
must be removed or disabled, depending on the design of the door,
it could be possible to manually raise the door approx. 50 mm.
To counteract this, spring catches can installed to lock the door
in addition to the operator.
These spring catches are connected to the operator by means
of a locking set; when opening a door, the spring catches must
first be disengaged before the operator can open the door.
Important information!
Additional pulse transmitters are: Handheld transmitters,
Telecody, wireless indoor switches and key switches.
In the case of the handheld transmitter, Telecody
or the wireless indoor switches, a connecting line
to the operator is not required; consult your dealer.
Selection of installation variants
Caution!
The chain cover is not packaging.
Do not remove it!
Important information!
Select the variant you wish to install. Convert the power feed
for variant (A).
Installation variant A Installation variant B
V
V
7
AB

Installation
10
Preinstallation of installation
variant A
Important information!
Dispose of the packaging according to locally applicable
regulations.
• Remove the operator from the packaging.
1
2
1
• Loosen the guide idler (1) and push it in the direction of the arrow;
fold out the chain guide (2).
N
2
1
3
2
4
3
3
3
2
• Slide the carriage (1) onto the chain (2) with chain guide (4).
The chain (2) engages in the chain wheel (3).
If the chain wheel (3) does not rotate, pull once on the emergency
release cord (N). The chain wheel (3) is then unlocked.
2
1
3
1
1
2
4
• Push trolley (1) onto C-track (2).
• Insert two C-track parts (1) in the connecting sleeve (2)
up to the stop position.
C
A
B
90°
D
a
c
90°
b
1
2
3
4
5
6
V
V
5
• Attach tensioner (1) to chain (2) and turn it 90°. Insert connecting
element (6) and push tensioner (1) through it. Put U-washer (5)
and spring (4) on the tensioning bolt (3) and screw the tensioning
bolt (3) into the tensioner (1).
6 7
• Tighten the chain as far as the mark (arrow).
• Don't tighten here; pretensioned at the factory.
8
• Disassemble the two steel brackets with washers and toothed lock
washers from the ceiling suspension bracket.
910
• Push the ceiling suspension bracket (1) onto the C-track (2).
• Mount bracket (2) with screw (1) and nut (3) on the connecting
element (4).
1
2
3
4
5
6
7
8
9
10