BUTZBACH NOVOSPRINT Duo User manual

Operating manual
High-Speed Doors NOVOSPRINT®

Butzbach GmbH Industrietore Originalbedienungsanleitung NOVOSPRINT_V1 24/02/2021 I
Masthead
Copyright by Butzbach GmbH Industrietore, Weiherstraße 16, D-89293 Kellmünz
All rights reserved. This manual may not be reproduced or disseminated in any manner without the prior
consent of Butzbach GmbH Industrietore.
Butzbach GmbH Industrietore reserves the right to make changes to illustrations and information in
this operating manual in order to incorporate technical advances. This operating manual was created with
great care and is revised regularly. However, despite all checks it cannot be ruled out that technical
inaccuracies and typographical errors were missed. All errors known to us will be removed in new editions, for
which reason we are grateful at all times for information about errors in this operating manual.
If this operating manual is not heeded, all warranty claims shall be void!
The operating manual should be kept near the door system for future use!
This operating manual applies to the following types of doors:
NOVOSPRINT®Duo
NOVOSPRINT®Mono
NOVOSPRINT®Syncro
NOVOSPRINT®SyncroL
NOVOSPRINT®SyncroXL

Butzbach GmbH Industrietore Originalbedienungsanleitung NOVOSPRINT_V1 24/02/2021 II
Contents
Masthead.............................................................................................................................................................I
1Preface........................................................................................................................................................1
1.1 About this manual...............................................................................................................................1
1.1.1 Target groups .................................................................................................................................1
1.1.2 Reading the manual .......................................................................................................................1
1.1.3 Contents of the manual ..................................................................................................................1
1.1.4 Save the manual.............................................................................................................................1
1.2 Symbol explanations ..........................................................................................................................2
2Safety ..........................................................................................................................................................3
2.1 Intended use.......................................................................................................................................3
2.2 Improper use.......................................................................................................................................3
2.3 Safety notices on the system..............................................................................................................4
2.4 Basic safety measures .......................................................................................................................4
2.4.1 Safety measures for commissioning and maintenance work.........................................................6
2.4.2 Operator obligations .......................................................................................................................6
2.4.3 Requirements for operating personnel...........................................................................................7
2.5 Safety devices ....................................................................................................................................8
3Other dangers .............................................................................................................................................9
3.1 Normally, the system does not present any dangers.........................................................................9
3.2 Other risks due to improper conduct ..................................................................................................9
3.3 Other risks during service and maintenance work ...........................................................................10
3.4 Other risks during emergency operation ..........................................................................................11
4Shipping and Storage................................................................................................................................12
5Design and Function .................................................................................................................................13
5.1 NOVOSPRINT®door types and options...........................................................................................13
5.2 Door movement function ..................................................................................................................13
5.3 Mechanical design............................................................................................................................14
5.3.1 NOVOSPRINT®Duo.....................................................................................................................14
5.3.2 NOVOSPRINT®Mono..................................................................................................................15
5.3.3 NOVOSPRINT®Syncro................................................................................................................16
5.3.4 NOVOSPRINT®SyncroXL............................................................................................................18
5.4 Door leaf construction.......................................................................................................................19
5.4.1 Door skin.......................................................................................................................................19

Butzbach GmbH Industrietore Originalbedienungsanleitung NOVOSPRINT_V1 24/02/2021 III
5.4.2 Vertical door leaf profile................................................................................................................19
5.4.3 Floor closure (optional).................................................................................................................19
5.5 Door frame material..........................................................................................................................19
5.5.1 Door jambs ...................................................................................................................................19
5.5.2 Upper cross beam ........................................................................................................................19
5.5.3 Door seal ......................................................................................................................................19
5.6 Door mounting..................................................................................................................................19
5.7 Door control unit ...............................................................................................................................20
5.7.1 Components of the NOVOSPRINT®control unit..........................................................................20
5.7.2 Traffic monitoring..........................................................................................................................20
5.8 Drive mechanism..............................................................................................................................20
5.9 Safety devices ..................................................................................................................................21
5.9.1 Sensitive edge..............................................................................................................................21
5.9.2 Light curtain (optional)..................................................................................................................21
5.9.3 Stationary light curtain or light beam (optional)............................................................................21
5.9.4 Safety sensors (optional)..............................................................................................................21
5.9.5 Crash protection with spring-loaded stay bar (optional)...............................................................21
5.9.6 Spring breakage monitoring (with the FRW option) .....................................................................21
6Control and display elements....................................................................................................................23
6.1 Control elements ..............................................................................................................................23
6.1.1 Definition and placement..............................................................................................................23
6.1.2 Main switch (dial)..........................................................................................................................23
6.1.3 Control unit variants......................................................................................................................23
6.1.4 External signal transmitter............................................................................................................25
6.1.5 Movement detector self-monitoring (optional)..............................................................................26
6.2 Display elements ..............................................................................................................................26
7Operation...................................................................................................................................................27
7.1 Electrical connection.........................................................................................................................27
7.1.1 Requirement.................................................................................................................................27
7.1.2 Connection....................................................................................................................................27
7.1.3 Commissioning.............................................................................................................................27
7.1.4 Inspection of safety devices .........................................................................................................28
7.2 System operation..............................................................................................................................28
7.3 Switching the system off...................................................................................................................29

Butzbach GmbH Industrietore Originalbedienungsanleitung NOVOSPRINT_V1 24/02/2021 IV
7.4 Emergency operation (lever)............................................................................................................29
7.4.1 Opening with the lever..................................................................................................................30
7.4.2 Full opening (if needed)................................................................................................................31
7.5 Lock for emergency operation (lever)...............................................................................................31
7.5.1 Opening with the aid of the lever lock ..........................................................................................32
8Care and Cleaning ....................................................................................................................................33
9Maintenance and inspection .....................................................................................................................34
9.1 Basics for testing power-operated doors..........................................................................................34
9.1.1 Safety requirements .....................................................................................................................34
9.1.2 Annual testing / Technical rule ASR A1.7 ....................................................................................34
9.1.3 Qualified individual .......................................................................................................................34
9.2 Maintenance and Inspection Work...................................................................................................35
9.2.1 Inspection of safety components..................................................................................................35
9.2.2 Reasons for extraordinary inspection...........................................................................................36
9.2.3 Testing by a qualified individual....................................................................................................36
9.2.4 Inspection and maintenance plan for consumable parts for NOVOSPRINT®doors....................37
10 Malfunctions and Repairs......................................................................................................................38
10.1 Explanation of terms.........................................................................................................................38
10.1.1 Malfunction ...............................................................................................................................38
10.1.2 Repairs .....................................................................................................................................38
10.2 Objective...........................................................................................................................................38
10.3 Malfunctions and remedies...............................................................................................................38
11 Dismantling and Disposal......................................................................................................................39
11.1 Dismantling the system ....................................................................................................................39
11.2 Disposal of the system .....................................................................................................................39
11.3 Customer service address................................................................................................................39
11.4 Door details.......................................................................................................................................39
Index.................................................................................................................................................................40

Preface
Butzbach GmbH Industrietore Originalbedienungsanleitung NOVOSPRINT_V1 24/02/2021 1
1 Preface
1.1 About this manual
1.1.1 Target groups
The target groups of this operating manual are:
the system operator for operation and training
the professional operating personnel for operation
the trained maintenance personnel for maintenance
The target groups must be familiar with the system, have read and understood this operating manual and know
and follow the relevant safety regulations!
1.1.2 Reading the manual
Read this manual carefully before working on the system and become familiar with the operation of the door
system. Respect the content and heed the safety instructions contained in this operating manual, both for your
own safety and that of your colleagues, but also to ensure a longer operational life of the door system. Non-
compliance can lead to damage to the door system and personal injury.
Also follow the local legal regulations and the state of the art.
The model of your door system may vary depending on:
specific agreements for the order
installation situations
general conditions
Therefore, the description may differ from your door system in individual cases. Items that are not included as
standard in every door system are labelled as optional.
1.1.3 Contents of the manual
This manual should make you familiar with:
necessary safety measures before and while working on the system
the operational functions of the system
steps to take when malfunctions occur in the system
repair work that can be carried out by operating personnel.
Description of system assembly is not a component of this operating manual.
1.1.4 Save the manual
Save the manual in a safe place in the immediate vicinity of the door system that is accessible at all times.
Note!
Please see the System Data.
This is a separate document, specific to the door!

Preface
Butzbach GmbH Industrietore Originalbedienungsanleitung NOVOSPRINT_V1 24/02/2021 2
1.2 Symbol explanations
Safety notices and additional information are marked with the following symbols and signal words in this
operating manual. The signal words signalise the extent of danger to be expected.
The following presentation is used for labelling instructions:
✔Requirement for the next described instruction
1. First instruction step
2. Second instruction step
3. etc.
Danger / Warning / Caution!
When using the symbols, it is also stated whether it is a danger or warning or whether caution is warranted.
Danger:
This notation indicates a great danger, the type and source of which can lead to severe
injuries, mortal danger or death.
Warning:
This notation warns of a source of danger, which may lead to mild to severe injuries and
major property damage if not heeded.
Caution:
This notation warns of a source of danger, which may lead to mild to injuries and minor
property damage.
Danger from electrical current!
This indication warns of danger from electrical current. Not heeding it can lead to severe injuries, mortal
danger, or death.
Note!
A note shall make things easier, e.g. by
providing tips for better handling
pointing out not immediately noticeable circumstances / situations.
providing information about explanatory documents, e.g. guidelines, standards, etc.

Safety
Butzbach GmbH Industrietore Originalbedienungsanleitung NOVOSPRINT_V1 24/02/2021 3
2 Safety
2.1 Intended use
The NOVOSPRINT®high-speed door is intended for installation in personnel access areas. NOVOSPRINT®
shall allow for safe access for goods and vehicles accompanied by people, mainly in the interior areas of
industrial and commercial zones of facilities.
2.2 Improper use
Note! Intended use!
Only applicable in Germany: Use of the door system as an exit and escape route is possible in certain
situations.
Warning! Danger in the case of improper use!
The improper use of the door system may lead to dangerous situations.
In its standard version, the system is not intended for the following use:
Use in areas at risk of explosions
Use in areas where fire protection regulations apply
Use of the motor to drive or control third party devices
Use in areas where children or unauthorised parties have access to operation of the system

Use with accessories and replacement parts, which are not controlled and approved by Butzbach
GmbH Industrietore
Use without or with non-functioning safety devices
Use of the emergency operation function for normal opening

Safety
Butzbach GmbH Industrietore Originalbedienungsanleitung NOVOSPRINT_V1 24/02/2021 4
2.3 Safety notices on the system
The following safety notices are affixed to the system, and they must be heeded:
2.4 Basic safety measures
Danger! Mortal danger of electric shock!
When opening the electrical cabinet / mains connection box / door control unit, line voltage is present!
Mortal danger!

Disconnect the control unit from the mains (main power switch) before you open the electrical
cabinet or mains connection box! After disconnecting the supply voltage, there is still
residual voltage present for up to ten minutes. The control unit may not be opened during this time.
Mortal danger!
Work on the electrical system should only be carried out by a qualified electrician.

When performing any work on the electrical system, the qualified electrician must comply with the
five rules of safety (BGUV regulation 3) and the relevant VDE regulations.
The system must be securely disconnected from the mains during all installation work!
Warning! Danger of being crushed in the building edges, the
building wall, and the door leaves!
Risk of injury in the door reveal, the supports and the wall!
Neither people nor objects may be between the door leaves.
Warning! Danger of being crushed in the building edges and the
door leaves!
Risk of hand injuries, e.g. by reaching into the area of the door reveal, the supports, the walls and between
the door leaves!
Neither people nor objects may be between the door leaves!
Danger! Mortal danger of electric shock!
Connections that are not made correctly or not professionally may lead to death and extremely severe
injuries! In addition, they may lead to the system no longer being able to be operated safely.
Work on the electrical system should only be carried out by a qualified electrician.

Safety
Butzbach GmbH Industrietore Originalbedienungsanleitung NOVOSPRINT_V1 24/02/2021 5
Danger! Never disable safety devices!
Never disable safety devices or bypass them.
Do not operate the system if safety devices are damaged!
Warning! Injuries and damage when working on the system!
Make sure that electricity has been disconnected from the control unit when working on the system. Risk
of injury and risk of damage!

Ensure that the main power switch is guarded against being turned back on without authorisation
with a hanging lock or that the CEE plug is guarded against being plugged in.
If multiple people are working on the system, each one
must ensure that the main power switch
is secured against being turned on without authorisation.
Danger! Mortal danger of electrical shock due to residual voltage!
After disconnecting the supply voltage, there is still residual voltage present at the frequency converter
output in the control unit for up to ten minutes! The control unit may not be opened! Mortal danger of
electric shock! There is no electrical isolation at the output, i.e. there is line voltage present to PE or ground!
Mortal danger of electric shock!
Securely disconnect from the mains during all installation work!
Work on the electrical system should only be carried out by a qualified electrician.

Safety
Butzbach GmbH Industrietore Originalbedienungsanleitung NOVOSPRINT_V1 24/02/2021 6
2.4.1 Safety measures for commissioning and maintenance work
2.4.2 Operator obligations
In addition to this operating manual, the operator must comply with applicable safety, accident prevention and
environmental protection regulations for operation of the door system.
When doing so, the following should be noted:
The system may only be operated by authorised personnel who are familiar with its operation.
The operator must ensure that people entrusted with operation of the system have read and
understood the operating manual.
Warning! Blocking of the work area!
Block the work area prior to assembly, maintenance, and service work, in order to secure it from
unauthorised access by people and vehicles! Risk of injury!

When doing this, heed the national regulations (e.g. for Germany, the BG regulation BGV A 8 /
VBG 125, Section 12 “Obstacles and hazardous areas”requires that temporary obstacles and
hazardous areas be marked with red / white stripes).
Warning! Comply with the regulations, otherwise there is a
risk of injury!
When working on the system, always heed the legal regulations and safety notices, otherwise there is
a risk of injury!

Comply with the general legal regulations (safety, accident prevention, VDE standards) as well as
these safety notices.
The system may only be operated by authorised personnel who are familiar with its operation.

If the operator of the system does not have full visibility during operation, the operator must take
appropriate measures to ensure operational safety.
Always perform work on the system with sure footing!

Do not wear loose clothing, jewellery, etc. when working on the system. They can be grabbed by
moving parts.

When working on the system, wear protective gloves, safety shoes, a protective helmet and
protective goggles when performing machining activities.
In principal, avoid stopping in the door area.
Before operating the door system, ensure that no people or objects are located in the door area.
Hanging on and going for a ride during door movement is strictly forbidden!

Safety
Butzbach GmbH Industrietore Originalbedienungsanleitung NOVOSPRINT_V1 24/02/2021 7
In the case of doors with an uninterrupted power supply (UPS), the manufacturer's documentation
(attached to the device) must be followed!
The operator must ensure that the system is always visible during operation and that no people and/or
objects are in the closing area of the door during operation. If the operator of the door system does
not have full visibility during operation, the operator must take appropriate measures to ensure
operational safety and the protection of people or objects.
The system operator must ensure that the system is only operated in a technically flawless condition.
If there is possible damage, he must immediately have it inspected and repaired by Butzbach GmbH
Industrietore.
The system operator must ensure that the safety notices attached to the door system are
permanently visible.
The system operator must ensure that the safety devices are regularly (i.e. prior to commissioning
and, depending on need, however at least once annually) tested by a professional for proper
functioning. A test report should be kept of these required tests. This test report should be placed in
the door documentation.
In the case of systems with larger glass surfaces, the system operator must ensure that the
glass surfaces (especially at eye level) are made visible in order to avoid people running into the
glass surface (e.g. with stickers). The operator must ensure that this marking is always present to a
sufficient extent.
2.4.3 Requirements for operating personnel
The door system is only allowed to be operated by personnel who are familiar with its operation.
The operating personnel must fundamentally heed the following safety notices:
Warning! Risk of injury when operating the system in the presence
of wind!
Operating the door in the presence of wind may lead to a risk of injury and property damage in certain
circumstances!
Warning! Do not operate the door system when under the influence
of alcohol or drugs!
Operating the door system when under the influence of alcohol, drugs, narcotics, etc. is forbidden. Risk of
injury and risk of property damage!

Safety
Butzbach GmbH Industrietore Originalbedienungsanleitung NOVOSPRINT_V1 24/02/2021 8
2.5 Safety devices
In exceptional cases, e.g. in the event of a power outage, the door may be opened by hand with the lever
(sealed). It is mandatory to heed the safety notices. Emergency operation may only occur in accordance with
the information in 7.4 Emergency operation.
Important! This device is only provided for doors that do not automatically open in the event of a
power outage.
The door systems are equipped with safety devices, which are described in the chapters discussing the
functions.
Warning! Risk of injury from non-functioning safety devices!
Non-functioning safety devices may lead to death or extremely severe injuries.
Regularly check the safety components in accordance with the information in 9.2.1
Inspection of
safety components.

Other dangers
Butzbach GmbH Industrietore Originalbedienungsanleitung NOVOSPRINT_V1 24/02/2021 9
3 Other dangers
3.1 Normally, the system does not present any dangers
If the assembly work is performed according to regulations, the safety devices are functioning flawlessly and
the system is used as intended, there is normally no danger to people and objects.
3.2 Other risks due to improper conduct
Note! Regular operation!
Ensure that

the system is always visible during operation and that no people and/or objects are in the closing
area of the door during operation.

otherwise appropriate measures were taken to ensure operational safety and the protection of
people or objects.
Warning! Risk of injury from leaning on the door skin!
Risk of injury, since you can be run into by the door leaf bar if the door opens suddenly, or you can have
a risk of falling if the door skin gives way!
Never lean against the door skin!
Warning! Risk of injury due to reaching into the functional gap at the
door jamb!
Risk of injury due to the hand possibly being pulled in!
Never reach into the functional gap by the door jamb!
Warning! Risk of injury from reaching into openings and gaps,
e.g. at the cross beams and in the stay bars!
Risk of injury due to possibly being grabbed and thereafter severe crushing of the hand!
Important! This especially applies during door operation and for doors with a low building design.
Always stay a sufficient distance back from the door!
Never reach into gaps and openings, e.g. at the cross beams!

Other dangers
Butzbach GmbH Industrietore Originalbedienungsanleitung NOVOSPRINT_V1 24/02/2021 10
3.3 Other risks during service and maintenance work
Warning! Risk of injury from unexpected opening of the door!
The door system could open unexpectedly on its own or be opened by other people.
Always remain aware when you are in the door area.
Do not lean any ladders against the door.
Warning! Injuries and damage when working on the system!
Risk of injury and risk of damage.

Make sure that electricity has been disconnected from the control unit when working on
the system.

Ensure that the main power switch is guarded against being turned back on without authorisation
with a hanging lock and that the CEE plug is guarded against being plugged in.
If multiple people are working on the system, each one
must ensure that the main power switch
is secured against being turned on without authorisation.
Warning! Comply with the regulations, otherwise there is a
risk of injury!
When working on the system, always heed the legal regulations and safety notices, otherwise there is a
risk of injury!

Comply with the general legal regulations (safety, accident prevention, VDE standards) as well as
these safety notices.
The system may only be operated by authorised personnel who are familiar with its operation.

If the operator of the system does not have full visibility during operation, the operator must take
appropriate measures to ensure operational safety.
Always perform work on the system with sure footing!

Do not wear loose clothing, jewellery, etc. when working on the system. They can be grabbed by
moving parts.

When working on the system, wear protective gloves, safety shoes, a protective helmet and
protective goggles when performing machining activities.
In principal, avoid stopping in the door area.
Before operating the door system, ensure that no people or objects are located in the door area.
Hanging on and going for a ride during door movement is strictly forbidden!

Other dangers
Butzbach GmbH Industrietore Originalbedienungsanleitung NOVOSPRINT_V1 24/02/2021 11
3.4 Other risks during emergency operation
In exceptional cases, e.g. in the event of a power outage, the door may be opened by hand with the lever.
It is mandatory to heed the following safety notices.
Warning! The safety devices are out of service during emergency
operation!
The safety devices are out of service during emergency operation. Therefore, it is mandatory to heed the
following safety notices:
Ensure that no people or objects are in the vicinity of the door.
Monitor the non-visible areas with additional personnel.
Move the emergency operation lever slowly in a controlled manner.

Shipping and Storage
Butzbach GmbH Industrietore Originalbedienungsanleitung NOVOSPRINT_V1 24/02/2021 12
4 Shipping and Storage
The shipping and delivery of the door system occurs a certain amount of time prior to the assembly date.
However, the door system is not assembled immediately after delivery.
Externally visible shipping damage must be marked on the shipping documents and a complaint must
be made immediately. Claims for compensatory damages may only be asserted within the applicable
complaint periods.
Packaging for the door system is selected in accordance with the expected shipping conditions.
The packaging may not be damaged or removed before the final assembly in order to protect
the door system.
The buyer / operator / customer must ensure proper storage in these cases. Proper storage is
understood to be the following:
Protection from direct sunlight!
Protection from moisture and dampness!
Packages may not be stacked!
The notices attached to the packaging regarding storage must be followed.

Design and Function
Butzbach GmbH Industrietore Originalbedienungsanleitung NOVOSPRINT_V1 24/02/2021 13
5 Design and Function
5.1 NOVOSPRINT®door types and options
Door type
Description
Duo
NOVOSPRINT®Duo is the variant with individual leaf control. Both door leaves can be
opened independently of one another.
Mono
NOVOSPRINT®Mono is the single leaf variant of NOVOSPRINT®. The door can be
opened either to the left or to the right.
Syncro + SyncroL
With NOVOSPRINT®Syncro and SyncroL, both door leaves open synchronously to the
right and to the left.
SyncroXL
NOVOSPRINT®SyncroXL is the larger version of NOVOSPRINT®Syncro.
Option
Description
Double-walled door leaf
Door leaf with skin in a double-walled version (not for SyncroL and SyncroXL)
Floor closure
Optional lowering mechanism that closes the gap between the door and the floor.
Escape route
For use in exit paths and escape routes
Hygiene
Increased corrosion protection, since primarily made of stainless steel
Sprint
Increases the opening and closing speed (not for SyncroL and SyncroXL)
5.2 Door movement function
There are galvanised spring tubes made of thin steel pipes with integrated torsion springs located in the side
door jambs:
The door skin rolls to the side during the opening process.
The door panel moves toward the centre during the closing process. The door skin is rolled / unrolled
by the spring tube.
The door can be opened with control buttons and, as the standard option, closes again after the closing delay
time has passed. As an option, the signal to open can also be sent from a detector.

Design and Function
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5.3 Mechanical design
5.3.1 NOVOSPRINT®Duo
Diagram 1 Mechanical design of NOVOSPRINT®Duo (top = single wall, bottom = double wall)
Legend
01 Cross beams
10 Lower covering (optional)
02 Mounting bracket
11 Jamb covering (optional)
03 Wire channel
12 Closing edge with sensitive edge
04 Emergency operation
13 Movement detector*
05 Electrical cabinet
14 Item omitted
06 Stay bar
15 Spring breakage monitoring*
07 Lower mounting bracket
16 Door skin with vision element
08 Functional gap
17 Wire channel (Duo)
09 Upper covering
18 Emergency operation (Duo)
* Only for doors in exit paths and escape routes

Design and Function
Butzbach GmbH Industrietore Originalbedienungsanleitung NOVOSPRINT_V1 24/02/2021 15
5.3.2 NOVOSPRINT®Mono
Diagram 2 Mechanical design of NOVOSPRINT®Mono (top = single wall, bottom = double wall)
Legend
01 Cross beams
09 Upper covering
02 Mounting bracket
10 Lower covering
03 Wire channel
11 Jamb covering (optional)
04 Emergency operation
12 Closing edge with sensitive edge
05 Control cabinet; control button; main switch
13 Movement detector*
06 Rigid stay bar
14 EMERGENCY OPEN button*
07 Lower mounting bracket
15 Spring breakage monitoring*
08 Functional gap
16 Skin with vision element
* Only for doors in exit paths and escape routes