Genius MILORD 5 User manual

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ENGLISH
Notes on reading the instruction
Read this installation manual to the full before you begin installing the product.
The symbol indicates notes that are important for the safety of persons and for the good condition of the automated system.
The symbol draws your attention to the notes on the characteristics and operation of the product.
CE DECLARATION OF CONFORMITY FOR MACHINES
(DIRECTIVE 98/37/EEC)
Manufacturer: GENIUS S.p.A.
Address: Via Padre Elzi, 32 - 24050 - Grassobbio- Bergamo - ITALY
Declares that: Operator mod. MILORD 5 - MILORD 8 - MILORD 424
is built to be incorporate in a machine or to be assembled with other machinery to create a machine under the provisions of Directive 98/37/EC;
conforms to the essential safety requirements of the other following EEC directives:
73/23/EEC and subsequent amendment 93/68/EEC.
89/336/EEC and subsequent amendment 92/31/EEC and 93/68/EEC
Furthermore, the manufacturer declares that the machinery must not be put into service until the machine into which it will be incorporated or of which
it will become a part has been identified and its conformity to the conditions of Directive 98/37/EC has been declared.
Grassobbio, 01-06-2006
Managing Director
D. Gianantoni
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INDEX
1. DESCRIPTION AND TECHNICAL SPECIFICATIONS page.7
2. ELECTRICAL SET-UP page.7
3. INSTALLING THE AUTOMATED SYSTEM page.7
3.1. PRELIMINARY CHECKS page.7
3.2. INSTALLING THE OPERATOR page.7
3.3. INSTALLING THE RACK page.8
3.4. POSITIONING THE STROKE-LIMIT MAGNETS page.9
4. START-UP page.10
5. AUTOMATED SYSTEM TEST page.10
6. MANUAL MODE OPERATION page.10
7. SPECIAL APPLICATIONS page.10
8. MAINTENANCE page.10
9. REPAIRS page.10

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MILORD AUTOMATED SYSTEM
The MILORD automated system for residential sliding gates is an electro-
mechanical operator which transmits motion to the leaf through a pinion
gear suitably coupled to a rack fitted on the gate.
The non-reversing system ensures mechanical locking when the motor
is not operating and, therefore, installing a lock is unnecessary. A handy
release facility makes it possible to move the gate in the event of a power
cut or fault.
This operator has no mechanical clutch, and, therefore, requires a control
unit with electronic clutch.
In the “C” versions, MILORD operators have the electronic control unit built
into the operator body.
1. DESCRIPTION AND TECHNICAL SPECIFICATIONS
teChniCal speCifiCations of operators
Model MILORD
5-5C
MILORD
424-424C
MILORD
8-8C
Power supply 230V~ 50Hz 24 Vdc 230V~ 50Hz
Absorbed power 350 W 70 W 500 W
Absorption 1.5 A 3 A 2.2 A
Electric motor rpm 1400
Thrust capacitor 10 µF 400V / 12.5 µF
400V
Reduction ratio 1:25
Pinion Z16
Rack module 4
Max torque 18 Nm 13.5 Nm 24 Nm
Max thrust 45 daN 40 daN 65 daN
Thermal protection on winding 140°C / 140°C
Use frequency 30% 100% 40%
Operating ambient temperature -20°C +55°C
Operator weight 10 Kg 11Kg
Protection class IP44
Max gate weight 500 Kg 400 Kg 800 Kg
Gate speed 12 m/min
Max gate length 15 m
1 Gearmotor 6 Magnetic sensor
2 Protective housing 7 Foundation plate
3 Control unit * 8 Pinion
4 Toroidal transformer ** 9 Release device
5 Encoder **
* Standard supply only in “”C”” versions
** For MILORD 424C model only
1 Gearmotor 6 Magnetic sensor
2 Protective housing 7 Foundation plate
3 Control unit * 8 Pinion
4 Toroidal transformer ** 9 Release device
5 Encoder **
* Standard supply only in “”C”” versions
** For MILORD 424C model only
Fig. 1Fig. 1
2. ELECTRICAL SET-UP
(standard system)
3X1,5mm
2
2
2
5
4
1
230V~
3x0,5 mm
2
2x0,5 mm
2
2x0,5 mm
2
2x1,5 mm
2
3x0,5 mm
2
3
3. INSTALLING THE AUTOMATED SYSTEM
3.1. PRELIMINARY CHECKS
To ensure a correctly operating automated system, the structure of the
existing gate or gate to be built must satisfy the following requirements:
the weight of the gate must comply with the data in the technical spe-
cifications table;
sturdy, rigid gate structure;
smooth leaf surface (without any projections);
smooth, uniform gate movement, without any friction during the entire
travel;
no sideward leaf swings;
top and bottom sliding systems must be in excellent condition. It is prefe-
rable to use a ground-level guide with rounded groove to obtain reduced
sliding friction.
only two sliding wheels;
mechanical safety stops required to prevent the danger of gate derail-
ment; these stops must be firmly secured to the ground or to the ground-
level guide at about 40 mm beyond the travel limit position.
no mechanical closing locks.
We advise you to carry out the metalwork jobs before installing the auto-
mated system.
The condition of the structure directly influences the reliability and safety
of the automated system.
3.2. INSTALLING THE OPERATOR
Assemble the foundation plate as in Fig.3.
Dig a cavity for the foundation plate as shown in Fig. 4. The foundation
plate must be located as shown in Fig. 5 (right closing) or Fig.6 (left closing)
to ensure correct meshing between rack and pinion.
We advise you to place the plate on a cement base about 50 cm
off the ground (fig.7).
Lay the flexible pipes for routing the connection cables between gear-
motor, accessories and electrical power supply. The flexible pipes must
protrude by about 3 cm from the hole on the plate.
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1.
2.
3.
Operator with built-in control unit (supply a suitable foundation plate)
Photocells
Key push-button
Flashing lamp
Receiver
1) To lay cables, use adequate rigid and/or flexible tubes.
2) Always separate connection cables of low voltage accessories
from those operating at 230 V~. To prevent any interference wha-
tever, use separate sheaths.
1.
2.
3.
4.
5.
Operator with built-in control unit (supply a suitable foundation plate)
Photocells
Key push-button
Flashing lamp
Receiver
1) To lay cables, use adequate rigid and/or flexible tubes.
2) Always separate connection cables of low voltage accessories
from those operating at 230 V~. To prevent any interference wha-
tever, use separate sheaths.
1.
2.
3.
4.
5.
Fig. 2Fig. 2

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Wall in the plate perfectly levelled.
Wait for the cement to set in the cavity.
Lay the electrical cables for connection to the accessories and the
electrical power supply (paragraph 2). To facilitate making the electrical
connections on the control unit, make the electric cables protrude by
about 20 cm from the hole on the foundation plate.
Secure the operator on the foundation plate, using the supplied screws
and washers as shown in Fig. 8. The operator’s position is shown in Fig. 7.
When positioning the operator, route the electrical cables through the
hole on the base of the gearmotor body.
Route the connecting electrical cables through the hole on the base of
the unit’s support, using the supplied cable gripper.
Make the electrical connections to the electronic control unit according
to the instructions for the unit.
1) Connect the earth cable of the system.
2) The operator is supplied for installation with the gate closing on the
right of the operator (looking from the inside) (fig. 5). If you require
left-hand closure, change over the connection of the cables con-
nected to the terminals of the motor.
The dimensions in the figures are in mm.
3.3. INSTALLING THE RACK
PPrepare the rack (supplied on request), with the supplied Hex-head 8 x
25 screws, and spacers to be welded, as shown in Fig. 9. To avoid having
to weld on the gate, galvanised through-spacers and Hex-head 8 x 50
securing screws are available.
We advise you to tighten the securing screws of the rack on the top
end of the slot. This position will enable you to raise the rack when
the gate tends to lower through time.
Release the operator (see paragraph 6).
4.
5.
6.
7.
8.
9.
1.
2.
Fig. 7Fig. 7
Fig. 8Fig. 8
~50mm
212 mm
180 mm
~100 mm
~240 mm
84 mm
45 mm
~200 mm
Fig. 3
Fig. 4
Fig. 5
Fig. 6

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Manually move the leaf to its open position.
Lay the first element of the rack on the pinion, on the first spacer (fig.
10).
Secure the rack element to the leaf with a clamp (fig. 10).
Manually slide the leaf toward the closing point until you reach the rack’s
third spacer, and fix it with a weld spot.
Definitively weld the three spacers on the gate. Procedure for correctly
fixing the other rack elements required to reach the closing position:
Bring near another rack element to the last fixed element, using a piece
of rack to synchronise the teeth with the two elements (fig. 11).
Manually slide the leaf toward the closing point until you reach the pinion
with the third spacer of the element to be secured (fig. 11).
Make sure that all the rack elements work on the centre of the pinion’s
teeth. Otherwise, adapt the gearmotor’s position.
Weld the element’s three spacers (fig. 10).
a) Do not, on any account, weld the rack elements either to the
spacers or to each other.
b) Do not, on any account, use grease or other lubricants between
rack and pinion.
3.
4.
5.
6.
7.
8.
9.
10.
Fig. 9Fig. 9
Fig. 10Fig. 10
Fig. 11Fig. 11
To obtain correct play between rack and pinion, lower the gearmotor by
1.5 mm, using the nuts supporting the foundation plate. When you have
finished adjusting, correctly tighten the operator securing nuts.
If the gate was recently built, check this play (fig.12) a few months
after installation.
Manually check if the gate is free to open completely and if leaf move-
ment is good and friction- free.
3.4. POSITIONING THE STROKE-LIMIT MAGNETS
The operator has a magnetic limit-switch, which commands gate motion
to stop when the magnet, which is secured to the upper part of the rack,
activates the sensor. The magnets supplied with the operator are specifically
polarised and activate only one of the sensor’s contacts: the closing or
opening contact. The magnet activating the open gate contact bears an
open padlock symbol, and, vice versa, the magnet activating the closed
gate contact bears the closed padlock symbol (see Fig. 13).
Procedure for a correct positioning of the two stroke-limit magnets:
Assemble the two magnets as shown in figure 13.
Set the operator to manual mode operation - see chapter 6 - and
power up the system.
Manually take the gate to opening position, leaving about 40 mm from
the opening mechanical stop.
Allow the magnet, with the padlock open, to slide on the rack in opening
direction - see figure 14. As soon as the LED on the board, referring to the
opening limit-switch, goes OFF, take the magnet forward by another 10
mm and fasten it provisionally with the appropriate screws.
Repeat the operations from point 3 for the closing magnet.
Re-lock the system (see paragraph 6).
before sending a pulse, make sure that the gate cannot be moved
manually.
Command a complete gate cycle to check if the limit-switches are
operating correctly.
11.
12.
1.
2.
3.
4.
5.
6.
7.
1.5 mm 1.5 mm
Fig. 12Fig. 12
Fig. 13Fig. 13

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- To avoid damaging the operator and/or interrupting operation of the
automated system, leave a distance of about 40 mm from the safety
mechanical stops.
- Make sure that at the end of both the opening and closing manoeuvre,
the relevant contact stays active (LED OFF).
Change the position of the magnets as necessary and secure them
definitively.
4. START-UP
Program the control unit according to your needs, as per relevant
instructions.
Power up the system and check the condition of the LEDs according to
the table in the control unit instructions.
When you have run the automated system test (par.5), secure the pro-
tective housing on the operator, using the supplied screws as shown in
fig. 15.
5. AUTOMATED SYSTEM TEST
Check operating efficiency of the automated system and all accessories
connected to it.
Hand the customer the “User’s Guide” page and explain how the automa-
ted system operates correctly and how it should be used.
8.
1.
2.
3.
Fig. 14Fig. 14
Fig. 15Fig. 15
6. MANUAL MODE OPERATION
If the gate has to be moved manually due to a power cut or fault of the
automated system, use the release device as follows:
Using a coin, turn the lock clockwise until it stops (Fig. 16 ref. a)
Pull the lever as shown in fig. 16 ref. b.
Open and close the gate manually.
1
2
Procedure for restoring normal operation:
Cut power to the system.
Position the gate at about halfway of opening travel.
Take the release lever back into its position;
Using a coin, turn the lock anti-clockwise until it stops;
Restore power to the system.
when power is restored, command another complete opening
cycle.
before sending a pulse, make sure that the gate cannot be moved
manually.
7. SPECIAL APPLICATIONS
Applications other than those in this manual are EXPRESSLY PROHIBITED.
8. MAINTENANCE
To ensure correct long-term operation and a constant level of safety, we
advise you to generally check the system every 6 months. In the “User’s
Guide” booklet, there is a form for recording jobs.
9. REPAIRS
The User must not in any way attempt to repair or to take direct action and
must solely contact qualified GENIUS personnel or GENIUS service centres.
1.
2.
3.
1.
2.
3.
4.
5.
Fig. 16Fig. 16