FlexiForce ForceIQ Series User manual

forceIQ
manual
manual version 3.0
software version 1.147.c-1
DEF5000
EN

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CopyrightandDisclaimerNotice
Althoughthecontentsofthispublicationhavebeencompiledwiththegreatestpossiblecare,FlexiForcecannot
acceptliabilityforanydamagethatmightarisefromerrorsoromissionsinthispublication.Wealsoreservetheright
tomakeappropriatetechnicalmodifications/replacementswithoutpriornotice.
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Norightscanbederivedfromthecontentsofthisdocument.
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Colourguides:Colourdifferencesmayoccurduetodifferentprintingandpublicationmethods.
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CopyrightFlexiForceGroup2015.
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Allrightsreserved
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Contents
CopyrightandDisclaimerNotice      2
Contents         3
1.AboutthisManual        4
1.1SafetySymbolsUsedinthisManual    4
2.force70/100/140operator       5
2.1Safetyinstructions       5
2.2Preparation       5
2.3Electricalpreparations      5
2.4Assemblingthedriveunit      6
2.5Drawings/dimensions      7
3.forceIQcontrolunit        8
3.1Installation        8
3.1.1ForceIQ230Vsinglephasepreparation   9
3.1.2ForceIQ400Vpreparation    9
3.2Technicaldata       10
3.3forceIQmenuoverview      11
3.3.1AccesstheMenu      12
3.4Programming       12
3.4.1Changingthelanguage     13
3.4.2Motorsetup      14
3.4.3Adjustingtheendposition    16
3.4.4Safetydevice      18
3.4.5Operatingmode      20
3.4.6Codeentry      20
3.4.7Specialsetup      21
3.4.8Service       24
4.Optionalplugon        26
4.1ModuleBracket       26
4.2forceLD:LoopDetector      27
4.3forceRX4:Radioreceiver      28
4.4forceTL:TrafficLights      28
4.5forcePhotocells       29
4.6forceOCE        30
4.7forcePSE        30
4.8force668LMElectroniclock      32
5.Troubleshooting        32
6.Appendix         34
6.1Additionalfunctionterminals
6.2Wiringdiagrams
6.3Declarationofincorporation

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AboutthisManual
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AllusersandownersoftheIndustrialdoormustread,understandandobeytheinformationand
instructionsinthismanual.Failuretodosomayresultindamageto,orfailureoftheequipment,and
possibleinjurytopersons.
ThismanualcontainsfunctionaldescriptionsandinstallationinformationforanIndustrialdoor.When
informationorinstructionsareapplicabletoallthemethodsofoperationormodels,thereareno
operatortypesormodelnumbersinthetitle.Wheninformationorinstructionsareapplicableto
specificmethodsofoperationormodels,theapplicableoperationtypeormodelnumbersappearin
thetitle.
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1.1.SafetySymbolsUsedinthisManual
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Thefollowingsafetysymbolsareusedinthismanual:
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Indicatesageneralwarning
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Indicatesanelectricalhazard
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Specificusefulinformationconcerningtheinstallation.
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2. Force70XQ/100XQ/100XC/140XQoperator
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2.1. Safetyinstructions
•Followallinstructionssinceincorrectinstallationcanleadtosevereinjury.
•Checkthatthetemperaturerangemarkedontheoperatorissuitableforthelocation.
•Checkthatthedoorismovingsmoothandcorrectbeforeassemblingtheoperator.
•Checkthatthedoorisingoodmechanicalconditionandiscorrectlybalanced.
•Afterinstallation,ensurethatthemechanismisproperlyadjustedandthattheprotectionsystem
andanymanualreleasefunctioncorrectly.
•Ensurethatentrapmentbetweenthedrivenpartandthesurroundingfixedpartsduetothe
openingmovementofthedrivenpartisavoided.
•Externalpushbuttonunitsaretobelocatedwithindirectsightofthedoorbutawayfrom
movingparts.Unlessitiskeyoperated,itistobeinstalledataminimumheightof1,5mandnot
accessibletothepublic.
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2.2. Preparation
 Beforeyoustartmakesurethatthefollowingpreparationsaredone:
•Approval/communicationwithcustomercompleted.
•Materialsonsitearecomplete.
•Allmeasurementsarecorrect.
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2.3. Electricalpreparations
Themanuallyoperateddoorneedsnoelectricalsupply.Foranelectricallyoperateddoor,thefollowing
environmentcriteriaandelectricalsuppliesarerequiredfortheoperatortofunctionproperly:
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force100XQ/XC  force140XQ  force70XQ
Voltagesupply:+/10%  400VAC3phase50Hz,10A400VAC3phase50Hz,10A230VAC1phase50Hz,10A
Power:    0,37kW  0,55kW   0,50kW
Degreeofprotection:  IP54   IP54   IP54
Weight:    13kg   13kg   11,5kg
Alloweddoorweight,max.: 400kg   650kg   350kg
Temperatureworkingrange: 15°Cto+50°C  15°Cto+50°C  10°Cto+40°C
Operatingfactor,Dutycycle: 40%S310min.Intermittent40%S310min.intermittent 25%S310min.intermittent
Dimensionsforce..XQ(hxwxd): 375x260x110mm 375x260x110mm380x110x250mm
Dimensionsforce..XC(hxwxd): 425x110x260mm 
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2.4. Assemblingthedriveunit
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Thedoormustbecorrectlyinstalled,balancedandbeinclosedpositionbeforetheassemblyoftheoperator.
Fortheoperatoramountingattachmentof>500Nisrequired.
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1. Attachthefirststopringtotheshaft.
2. Attachthewallbracketwith4screwsandwasherstothemotor.
3. Pushtheoperatorcompletelyagainstthestopring.
4. Mountthewallbrackettothewallwithtwosuitablescrewsandwashers.
 Permountingattachment>500Nisrequired.
5. Disengagethedriveunitfromthedoorshaftbymovingthehandleclockwiseuntilitstops,
thenaimforthekeywaysatthedoorshaftandtheoperator.*Thewedgeshouldprotrudea
fewmmfromthewallbracket.
6. Attachthesecondstopring.Agapofafewmmshouldremainbetweenthestopringand
thewallbracket.
7. Tightenallscrews.
8. Routethecabledowntothecontrolunit.
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2.5 Drawings/dimensions
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Force100XQ/140XQ
Force100XC

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3.forceIQcontrolunit
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3.1Installation
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1. Attherearofthecontrolunityouhavetoassemble4enclosurebracketsbeforemountingitto
thewall.Usethefoursmall5x12screws.
2. MounttheControlunitapprox.1.7mabovethefloor(measuredfromtheuppersideofthe
box).
3. Connectthecablesfromthedoorleafandthedriveunit,accordingintheinstructionsbythe
wiringdiagram.Thecontrolunitisnowassembledandreadytobefunctionallyinstalled.See
paragraph"Programming"concerningtheprogrammingprocedure.
4. CheckthecontrolboardoftheForceIQifitispreparedfor230Vor400Voperator.Seenext
pagefortherightpreparation.
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3.1.1ForceIQ230Vsinglephasepreparation
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ConnectasbelowwhenyouusetheForceIQwitha230Vsinglephasemotor.
MakesureFuseF4is100mAmediumandthatKL131andKL132areconnectedtogether.
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3.1.2ForceIQ400Vpreparation
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ConnectasbelowwhenyouusetheForceIQwitha400Vmotor.
MakesureFuseF4is80mAslowandthatKL132andKL133areconnectedtogether.
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230V
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3.2Technicaldata

Dimensions(approx.): 345x215x135mm
MainsupplyvoltageL1,L2,L3,N,PE:forceIQ400V,50HZ/forceIQ230230V,50Hz.
Fuseprotection 10AKcharacteristic
Voltage 24VDC,max.320mA
Accessinput 24VDC,Allinputsmustbeabsolutelypotentialfreeconnected.
Minimumdurationofinputsignalcontrolcommand>100ms.
Safetycircuit/Emergencystop  Connectallinputsabsolutelypotentialfree;atinterruptionin
thesecuritycircuit,itisnotlongerpossibleofelectrical
operationofthemotor,eveninholdtorunmode.

Inputsafetyrail Forelectricalsafetystripswith8.2kΩ,loadresistorandfor
dynamicopticalsystems.
Relayoutput Ifusedaspowerswitchingcontacts,itcannotservemoresmall
electriccurrents.
Temperaturerange: 15°C+50°C
Protection IP54(inhousing)
Weight    Ca.2.2kg












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 

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3.3.forceIQmenuoverview

ForceIQ
______________________________________________________________

1. Display
2. Keypad
3. Pushbutton"UP"(dooropens)
4. Pushbutton"STOP"(doorstaysinposition)
5. Pushbutton"DOWN"(doorcloses)
Menuselection(left)
Menuselection(right)
Confirm
Changenumbervalues&endpositionsetting
1push,returntothemenuselection
2push,returntotheoperatingmode
Changenumbervalues&endpositionsetting.
 

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3.3.1.AccesstheMenu
1. PressandholdthepushbuttonSTOPfor6secondstoactivatethekeypadandtoaccessthe
menu.
2. Entertheaccesscode*.Younowhaveaccesstothemenu.Thedisplaywillshowplaintext
commands,messages,anderrormessages.Thekeypadisusedtonavigatethroughthemenu,to
confirmandtosave.*Standardaccesscodeis"00000".

3.4.Programming



BeforeprogrammingtheControlUnit:Makesurethatyouconnectalthedevices
likeintheBasicWiringDiagram.

•Placethedoor1.5mabovethefloor.
•Ensurethattheflooriscleanandfreefromcablesetc.
•Programmingcanonlybecarriedoutusingthesetofbuttonsinthecontrolbox,
notanexternalpushbuttonboxorradiocontrol.Fordoorswithsmalldrumsand
withoutsafetyfeatures,theremaybeariskofthecableunwinding.Check
thereforethatthecableisplacedcorrectlyonthedrum.



Inthemainmenuitispossibletoswitchbetweenthefollowingmenuitemsbypressing
the or button.
1)Language   13
2)Motorsetup  14
3)Adjustendposition 16
4)Safetydevice  18
5)Operatingmode  20
6)Codeentry  20
7)Specialsetup  21
8)Service   24

Pressthe buttontoentertheselectedmenu.

 

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3.4.1.Changingthelanguage
•usethe or buttonstoselectyourdesiredlanguage.
Dutch
German
English
Italian
French
Spanish
Polish
Swedish
Hungarian
Romanian

•Press toconfirmandsave.

•Press toreturntothemainmenu.
•Press oncemoretoenterthemaneuveringmode.

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3.4.2 Motorsetup

Usethe or buttonstoselectoneofthefollowingmenuitems:
1)Motordirection
2)Encoderdirection
3)Motorcontroller
4)Limitsw.type
5)Liftforcedetection
6)Inv.profileup (Onlyforinverteroperator)
7)Inv.profiledown (Onlyforinverteroperator)
8)Fuprofileboost (Onlyforinverteroperator)

1)Motordirection:Usethe or buttontochangethemotordirectionto"left"or"right".Press 
twicetoconfirm.

2)Encoderdirection:Usethe or buttonstochangetheencoderdirectionto"Clockwise"or"Anti
clockwise.Press twicetoconfirm.

3)Motorcontroller:Usethe or buttonstochoosebetween"Contactorrelay"and"Inverterrue"
Press twicetoconfirm.Use"Contactorrelay"forForceoperators.Choose"Inverterrue"forfrequencyconverters

4)Limitsw.type:Usethe or buttonstochoosebetweenseverallimitswitchtypes.Press twiceto
confirm.Fortheforce70/100/140controlunitchoose"Kostal"..Ifyouarenotsurewhatkindoflimitswitchyouhaveto
use,contactyouroperatorsupplier.

5)Liftforcedetection:Asdefaulttheliftforcedetectionisdisabled.Topreventthedoorfrombeingable
toliftaperson,theliftforcedetectionshallbeactivatedandadjustedtomakethedoorweaker.

Tosettheliftforcedetection,navigatetothe"Liftforcedet."menuitemandpress toselectthe
menuitem.

•Navigateto"Liftforcedet.Testdrive"Press .Holdtorunthedoordowntoclosedposition.
Thenrunuptofullyopenpositioninholdtorunmodeuninterrupted,torecordthenormaldoor
run(plot).

•Navigateto"Liftforcedet.up".Press andthedisplayshows"updisabled".
WiththeUPandDOWNbuttononecanenableandincreasetheliftforcedetectionfrom0,%
(disabled)to20%(strongest).Recommendedistostartat5%.
Press toconfirmselectedvalue.

•Press toreturntothemainmenu.Pressoncemoretoenterthemanoeuvringmode.
•Nowyoucanverifyifyoursettingisacceptableintheupwardsdirection.Ifthedooristoostrong
ortooweakrepeatstep2and3,thenverifythecurrentvalue.
NOTE!Thedoorrunsawhiletodetecttheweight.

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6)Inv.profileup Onlyforinverteroperator
Usethe buttonstoadjustthefollowingparameters:
•Maxspeed(Hz)themaximumspeedafteracceleration
•Minspeed(Hz)thespeedafterdeceleration
•Startramp(ms)accelerationtime
•Slowdownslope(ms)decelerationtime
•Stopramp(Incr.)valuebeforetheendpositionweretheslopehastostart
 Press toreturntothemainmenu.Press oncemoretoreturntothemanoeuvringmode


7)Inv.profiledown Onlyforinverteroperator
Usethe buttonstoadjustthefollowingparameters:

•Maxspeed(Hz)themaximumspeedafteracceleration
•Slowspeed(Hz)thespeedafterdeceleration
•Mediumspeed(Hz)thespeedafterreachpositionmediumspeed(seepoint8page14)
•Startramp(ms)accelerationtime
•Slowdownslope(ms)decelerationtime
•Stopramp(Incr.)valuebeforetheendpositionweretheslopehastostart

8)Fuprofileboost Onlyforinverteroperator
Usethe buttonstoadjustthefollowingparameters:

•Ratedfrequency(Hz)nominalfrequencyofthemotor
•Boost(%)toincreasethevoltagebylowfrequency


 

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3.4.3.Adjustingtheendposition

Warning:
Riskofmaterialdamage:Thedoorcouldbemovedbeyondtheupperandlowerendpositionmanuallyduring
installation(inholdtorunmode).Thismayresultindamagetothedoor.
Observethedoorduringsettingtheendpositionspermanently.


Beforeadjustingtheendposition:Placethedoorinthemiddleposition.Checkifthedoorgoesupwhenthe
buttonispushed.Ifthedoordoesnotgoupthenchangethedirectionofthemotor.(Seepage12"Motor
direction")

Usethe or buttonstoselectoneofthefollowingmenuitems:
1)Top
2)Bottom
3)Brakeoffset
4)Finepitchup
5)Finepitchdown
6)Preendposition
7)Safetylimit
8)Posmedspeed
Press toentertheselectedmenuitem.
1) Top:Runthedoorinthedesiredpositionusing or .press toconfirmendposition.


Checkifthecountercountsupwhenthedoorgoesup.Ifthecounterdoesn'tcountup,changethe
directionoftheencoder.(Seeparagraph"Motorsetup").

Usethe and buttontoselectthebottomadjustment.

2) Bottom:Runthedoorinthedesiredpositionusing or .Press toconfirmtheendposition.


Functioncontrol:Testthesafetyedgesettingbyusinga30x50mmgaugeblock.Rundownthedoortothe
50mmsideoftheblock,andthedoormustreverseupagain.Rundowntothe30mmsideoftheblock,
andthedoormuststop.Youcanadjusttheheightofthelimitwithpoint6"preendposition"

3) Brakeoffset:Usethe buttonstoadjustthisposition.Canbeusedforheavyandlightdoors.Seefor
moreinfonextpage.

4)Finepitchup:Ifneeded,usethe buttonstodefinetheexacttopendpositionofthedoor

5)Finepitchdown:Ifneeded,usethe buttonstodefinetheexactbottomendpositionofthe
door.
 

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17

6) Preendposition:Usethe buttonstoadjustthisposition.Thisisthepointwherethesafetyedge
changesfromreversetostopwhentriggered.

7) Safetylimit:Usethe buttonstoadjustthisposition.hereyoucanadjustthesafetylimitswitch.So
whenthedoorisrunningthroughtheendposition,thesafetylimitswitchwillautomaticlystoptheoperator.Defaultis
100
8)Positionmediumspeed(Onlyforinverteroperator):Usethe buttonstoadjustthisposition.The
positionmediumspeedisthepositionatwhichthedoorwillswitchfromfastspeedtomediumspeedwhenthe
doorismovingdown.
Pleaseletthedoorrunfourtimesupanddown.
Iftheendpositionsarecorrect,Press toreturntothemainmenu.Press oncemoretoreturntothe
maneuveringmode.


Afteradjustingtheendpositions,checkthequickreleaseorthesafetychainiftheyworkprobably.
Checkthiswhenthedoorisincloseposition.Whenitishardtomovethechainorquickrelease,thencheck
ifthereistensiononthecablesandspringsandifthedoorisnotpushingtootightonthefloor.




Brakeoffset

Thebrakeoffsetparameterisusedforautomaticmodewithencoder.Itistheinitialvaluewherethe
automaticbrakepointadjustmentfunctionswitchingonthebrakeandswitchingofthemotor.Thisfunction
detectswhenthedoordoesnotstoponthedefinedendpointandmodifiesthebrakeoffsetpoint.Fora
heavyorfastdoor,thedefaultvaluecanbetoolow.Inthiscasethedoorcanrunovertheendpositions.
Forsmallorslowdoors,thedefaultvaluecanbetoohigh.Inthiscasethedoorwillruntooshortinthefirst
23runsinautomaticmodeaftersettingtheendpositions.
Iftheendpositionsarechanged,thisfunctionneedstorunacoupleoftimesinautomaticmode,inorderto
getagoodmeasurementonwherethedoorstopsagain.

Thereisnoneedtodothefinetuningofendpositionswhenusinganencoder(providedthattheend
positionisinthecorrectplace).Insteadjustrunthedoorafewtimesinautomaticmodeandletthe
controllermanagetheadjustment.



 

manual – forceIQ
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18

3.4.4.SafetyDevice

Dependingofwhatkindofsafetydeviceisused,youcanchoosebetweenfollowing
actionswhensafetydeviceistriggered.

•Downfullreverse:doorreturnstotopendposition,byactivationwhiledoorisclosing.
•Downpartreverse:doorreturnsacoupleofcm,byactivationwhiledoorisclosing.
•Downstop:doorstops,byactivationwhiledoorclosing.
•Pullinprotect:doorstopsbyactivationwhiledoorgo'sup.
•Downfull/swoff:toadjustthepositiontodeactivatedthephotocellthatisactiveindownward
direction.Usethe buttonstoadjustthepositiontodeactivatedthephotocell.
•Pullinmasked:toadjustthepositiontodeactivatedthephotocellthatisactiveinupwarddirection
Usethe buttonstoadjustthepositiontodeactivatedthephotocell.

 Usethe or buttonstoselectoneofthefollowingmenuitems:

1)4wirephotocellKL5
2)2wirephotoKL6
3)OSE1setupKL3
4)OSE2setupKL4
5)Safety1KL212
6)Safety2KL234
7)ReverseDelay
8)Finepitchdisablephotoc.

Press toentertheselectedmenuitem.

1) 4wirephotocellKL5:Usethe or buttonstoselectoneofthefollowingmenuitems:

•Disabled:WhenKL5isnotinuse
•Lightcurtain:Whenalightcurtainisconnected
•Untested:Whenaphotocellisconnectedwithoutaselftest
•Tested:Whenaphotocellisconnectedwithaselftest(switchon24Vtestvoltagefortest)
•Testedinv.Whenaphotocellisconnectedwithaselftest(switchoff24Vtestvoltagefortest)


2) 2wirephotoKL6:Notinuse

3) OSE1setupKL3:Usethe or buttonstoselectoneofthefollowingmenuitems:

•Disabled:WhenKL3isnotinuse
•OSE:WhensafetydevicethatworkswithOSEsignalisconnectede.g.optosensors
•3wphotoc.:Whena3wiredphotocellisconnected

 

manual – forceIQ
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19


4) OSE2setupKL4:Usethe or buttonstoselectoneofthefollowingmenuitems:

•Disabled:WhenKL4isnotinuse
•OSE:WhensafetydevicethatworkswithOSEsignalisconnectede.g.optosensors
•WirelessOSE:WhenawirelessOSEsafetydeviceisconnected
•4wphotoc.:When4wiredphotocellisconnectede.g.prerunningphotocel

5) Safety1KL212:Usethe or buttonstoselectoneofthefollowingmenuitems:

•Disabled:WhenKL212isnotinuse
•8k2:whenasafetyedgeisconnectedthatdeactivated8.2kΩ
•Airwaveswitch:whenairwaveswitchwith8.2kΩisconnected.Thecontrolunitneedatestsignal
(deactivated8.2KΩ)fromtheairwaveswitcheverytimetheendpositionisreached
•Passdoor:whenasafetyedgeisconnectedthatdeactivated8.2kΩ.(specialpassdoormention)
•Testedpassdoor:radiosafetyedgeforpassdoor

6) Safety1KL234:Usethe or buttonstoselectoneofthefollowingmenuitems:

•Disabled:WhenKL234isnotinuse
•8k2:whenasafetyedgeisconnectedthatdeactivated8.2kΩ
•Airwaveswitch:whenairwaveswitchwith8.2kΩisconnected.Thecontrolunitneedatestsignal
(deactivated8.2KΩ)fromtheairwaveswitcheverytimetheendpositionisreached
•Passdoor:whenasafetyedgeisconnectedthatdeactivated8.2kΩ.(specialpassdoormention)
•Testedpassdoor:radiosafetyedgeforpassdoor

7) ReverseDelay:Usethe buttonstoadjustthisvalue
setthereversetimebetween20and600mSec.Selectingasmallervaluegivesyouafasterreversing,butalsoa
moredistinctrunningofthedoor,abiggervaluegivesasmooth,butlongerreversingsequence.Thedefaultvalueis
80mSec.

Warning:
ChangingtheReversedelayvaluewillinfluencethepeakforcevalueofthedoor


8) Finepitchdisablephotoc.:Usethe buttonstoadjustthisvalueHereyoucanfinepitchthe
"Downfull/swoff"positionfromwherethephotocellshavetobedisabled.(e.g.wherethephotocellsaremounted
inthedoorway).






 

manual – forceIQ
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20

3.4.5.Operatingmode

Usethe   buttonstoselectoneofthefollowingmenuitems:

•AutomaticUP/DOWN:thedooropensandclosesinautomaticmode.(onlyifsafetyedgesareokandactivated)
•DeadmanUP/Down:thedooropensandclosesinholdtorunmode
•AutomaticUP/DeadmanDOWN:thedooropensautomaticallyandclosesinholdtorunmode

IfAutomaticUP/DOWNisnotinthemenu,thenthereissomethingwrongwiththesafetydevicesorthe
connectedsafetydevicesisnotactivatedinthemenu.


Photocellsarenotsafeenoughaccordingsafetystandard,soyouwon'tfindautomaticUP/DOWNinthe
menu.ConnectonemoresafetyedgeforautomaticUP/DOWN.

Press toconfirmandsavethedesiredoperatingmode.
Press toreturntothemainmenu.
Press oncemoretoreturntothemanoeuvringmode


3.4.6.Codeentry
Usethe / / / tofillinthenewaccesscode.
Press onthelastdigittocomplete.
Press toconfirmandsavethenewcode.
Press toreturntothemainmenu.
Press toreturntothemaneuveringmode


 

Thefactorycodeis"00000"