GFA 10005484 00001 User manual

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Installation Instructions
ELEKTROMAT
SI 40.15-40,00 Ex
Model: 10005484 00001
-en-
Status: 19.10.2023

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GfA ELEKTROMATEN GmbH & Co. KG
Wiesenstraße 81
D-40549 Düsseldorf
www.gfa-elektromaten.de
[email protected]

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Table of contents
1General safety information .............................................................................................. 4
2Technical data ................................................................................................................ 6
3Technical data gearbox ................................................................................................... 7
4Technical data motor....................................................................................................... 8
5Technical data terminal box ............................................................................................ 9
6Technical data limit switch / switch emergency manual operation ................................... 9
7Integrated safety brake ................................................................................................. 10
8Mechanical installation .................................................................................................. 11
9Electrical installation ..................................................................................................... 15
10Limit switch setting ........................................................................................................ 18
11Motor connection .......................................................................................................... 20
12Limit switch connection ................................................................................................. 20
13Emergency manual operation (emergency hand crank) ................................................ 21
14Completion of commissioning / testing / operation ......................................................... 23
15Disposal ........................................................................................................................ 26
16Konformitätserklärung Zubehör ..................................................................................... 30
17Declaration of incorporation / Declaration of conformity ................................................. 32
18UKCA: Declaration of incorporation / Declaration of conformity ..................................... 33

Symbols
Warning - Potential injury or danger to life!
Warning - Danger to life from electric current!
Note - Important information!
▶ Requirement - Required action!
Schematic representations are based on product examples. Deviations from delivered
products are possible.

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1General safety information
Specified use
The drive unit is intended for doors that must be secured against dropping.
A safety brake is integrated into the gearbox. The drive unit must be mounted directly on
the shaft of the door. The drive unit can be used in hazardous areas thanks to its explosion
protection according to ATEX 2014/34/EU.
The drive unit must be protected against moisture and aggressive environmental
conditions (such as corrosive substances). The drive units are only suitable for indoor use.
Appropriate protective measures must be taken for outdoor installation. The values
specified in the technical data of the drive unit must not be exceeded. The safe operation
can only be ensured if used as specified.
Note - Only for installations in Australia
This Product has not been safety tested in accordance with Australian Standard
AS/NZS 60335.2.95:2020 Household and similar electrical appliances - Safety,
Part 2.95: Particular requirements for drives for vertically moving garage doors for
residential use for hazards when installed in residential environments.
Target audience of these installation instructions
These installation instructions are geared towards qualified persons trained in the handling
of door systems. Expert knowledge, relevant skills and practical experience are what set
apart qualified persons. They are capable of safely carrying out the tasks involving
installation, maintenance and modernisation according to the instructions.
Safe operation
The safe operation of the product can only be ensured if it is used as specified. Follow the
installation instructions. Observe all specifications, especially warnings, when installing the
product in the overall system. GfA is not liable for damage resulting from non-observance
of the installation instructions. The resulting overall system must be reassessed for its
safety in accordance with applicable standards and directives (e.g. CE marking). These
installation instructions refer only to a part of the overall system and are not sufficient as
the sole instructions for the overall system. The installer of the system must prepare the

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instructions for the overall system. We recommend entering the danger area of the system
only when the drive unit is at a standstill.
Warning - Failure to follow these installation instructions may result in severe injury or death.
Please read these instructions before using the product.
Keep these instructions handy.
Include these instructions when passing on the product to third parties.
Warning - Danger from improper use of the product!
Do not let children operate the product unsupervised or use as a toy.
Warning - Danger to life from incorrect installation!
Work carried out improperly may result in death or severe injury from electrical
current or falling parts.
Allow only competent people to carry out the work.
Disconnect all cables from the power supply.
Observe valid regulations and standards.
Use suitable tools.
Warning! Danger to life from falling objects if the drive unit is subjected to
impermissible forces.
Inadmissible forces (examples: collision with a forklift, dropping the drive unit, tearing
or pulling on the motor) lead to damage to the drive unit. There is a risk of severe
injury or death from falling objects.
Prevent impermissible forces from acting on the drive unit,
Check the drive unit for damage if impermissible forces have acted on it. Look
even for minor damage. Lock the door during the inspection.
Contact the service department if you have difficulty assessing the damage.

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2Technical data
Designation Unit
Output speed 15 rpm
Output torque 400 (240) 1) Nm
Output / hollow shaft 40,00 mm
Series SG 85F -
Limit switch range
(maximum revolutions of the output / hollow shaft)
20 -
Supply voltage 3~ 400 V
Operating current 2,00 A
Operating frequency 50 Hz
Power factor cos φ 0,70 -
Safety circuit 24 V
Degree of protection IP 65 -
Temperature range -20 / +40 °C
Operating sound pressure level < 70 dB(A)
Cycles per hour 10 (5,2)1) h-1
Max. holding torque 400 Nm
Locking torque 760 Nm
Safety brake (testing centre / approval number) 14-003612-PR03 -
Manual force emergency manual operation 227 N
Explosion protection II 2G Ex db eb h IIC T4 Gb
II 2D Ex tb h IIIC 130°C Db
Installation height < 1000 m

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Components used
Gearbox SG 85F 92.T4
Motor RL 80B4
Terminal box 8146/1041
Limit switch / emergency manual operation switch 07-2511
3Technical data gearbox
Designation
Series SG85F-92.T4
Manufacturer GfA
Explosion protection II 2G Ex h IIC T4 Gb
II 2D Ex h IIIC 130°C Db
Max. output torque 400 Nm
Max. output speed 19 min-1
Shaft centre distance 85 mm
Transmission ratio 1 : 92
Temperature range -20 / +40 °C
Protection class IP 65

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4Technical data motor
Designation
Type RL 80B4
Manufacturer RAEL MOTORI
ELETTRICI S.R.L
Explosion protection II 2G Exde IIC T4 Gb II 2D
Ex tb IIIC T135° Db
Certificate of verification CESI 20 ATEX 040 X
Supply voltage 230 / 400 V
Operating current 3,64 / 2 A
Operating frequency 50 Hz
Power 0,75 kW
Power factor cos φ 0,7
Motor speed 1440 min-1
Motor torque 5,2 Nm
Operating mode S1
Degree of protection IP66
Temperature class T4
Ratio IA / IN 4,9
Braking torque spring applied brake 10 Nm
Braking voltage 105 V DC
Operating current spring applied brake 1 A
Rectifier type DC
Temperature range -20 °C - 40 °C °C

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5Technical data terminal box
Designation
Type Ex e 8146/1041
Manufacturer Stahl
Explosion protection II 2G Ex e II T6
II 2D Ex tD A21 IP 66 T80°C
Certificate of verification PTB 01 ATEX 1016
Supply voltage 250 max. 1100 V
Terminal cross-section 2,5 mm2
Temperature range T6: -20 / +40
T5: -20 / +55 °C
Degree of protection IP 65
6Technical data limit switch / switch emergency manual operation
Designation
Type 07-2511-113061G
Manufacturer Bartec
Explosion protection II 2G Ex d IIC T6
II 2D Ex tD A21 IP 66 T80°C
Certificate of verification EPS 14 ATEX 1766 X
Supply voltage 400 V
Temperature range -20 / +40 °C
Degree of protection IP 66
C
AU
Component damage can result
The maximum allowable current applied to the limit switches is 2A 400V for AC-15 and
0.15 250V for DC-13.

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7Integrated safety brake
A safety brake is integrated into the gearbox of this ELEKTROMATEN. The safety brake
protects against the door dropping due to breakage or wear of the gear teeth. The safety
brake works regardless of the mounting position, speed and rotating direction. It is
maintenance-free. The specification of the locking torque and the approval number of the
safety brake are available in the technical data of these instructions.
Warning - Danger of the door dropping!
If you need to apply more than the permissible force of 390N (according to DIN EN
12604/DIN EN 12453) to move the door by emergency manual operation, this
indicates a stalling on the drive unit or door. Releasing the stalling may cause the
door to drop.
Adopt a secure position.
For drive units with brake, the emergency manual operation must be carried out
against the closed brake.

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8Mechanical installation
Warning – Explosion hazard!
 Check the atmosphere for explosion hazards before commencing installation tasks.
Requirements
The permissible loads on walls, mountings, connection and transmission elements must not
be exceeded even for maximum holding or locking torque (▶ observe technical data).
Connection elements
Use self-locking connection
elements with a minimum
strength of 800 N/mm2 (8.8).
Use a screw that precisely
fits the hole.
Use adequately
dimensioned washers for
elongated holes.
BAGAB00002_Z002 BAGAB00003_Z002
3 : 1

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Permissible mounting positions
BAGAC03005_Z001
Mounting
2 elongated holes are provided for mounting.
BAGAD03001_Z003

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Installation
The following descriptions refer to a door which is not further defined. The door
manufacturer's specifications must also be observed.
Warning – Injury or danger to life possible!
Use a lifting device with sufficient load-carrying capacity for installation tasks.
Completely grease the door shaft.
BAGAE01001_Z003
Mount the key.
BAGAE03002_Z001

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Attach the drive unit.
BAGAE3007_Z001
Tighten all connection elements (M12) with a
torque of 75 Nm. Install all further connection
elements according to the specifications of
the door manufacturer.
BAGAE03012_Z001
75 Nm
8.8
8.8
8.8 8.8

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9Electrical installation
Warning – Danger to life from electrical shock!
Disconnect the cables (mains OFF) and check that the supply is off
Observe the applicable regulations and standards
Ensure proper electrical connection
Use suitable tools
Carrying out the electrical installation
Remove the cover. Remove the cover.
Connect motor/limit switch connection cable

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Protection against overload
Motor protection switch / motor protection relay mains operation
The "Ex" motor must be protected against overload by means of a motor protection switch or
a motor protection relay. Only use motor protection relays with manual reset. Short-circuit
protection is also required. Excess current must be set on the basis of the IA / IN ratio.
PTC resistor signal mains operation
The motor is equipped with installed temperature sensors (PTC) which can be used as
overload protection. This protection class is approved as the sole protection against overload
for flameproof motors "d"; it must be equipped with a separate evaluation unit. The evaluation
unit measures the temperature of the motor coil and deactivates the motor as soon as the
preset temperature is exceeded. This safety device can only be reset by hand. Short-circuit
protection is also required.
PTC resistor signal frequency inverter operation
Evaluation is similar to that in mains operation. The motors have an additional rating plate.
The features on the additional rating plate must be checked before initial operation of the
motor. The connecting cable of the temperature sensors (PTC) must be routed separately to
the motor cable.
Frequency inverter operation!
Shielded motor cables must be used.
Shielded cables require separate cable glands.
The brake requires a separate supply line.

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Completing the electrical installation
Install cable entries and/or cable glands.
In order to achieve the required tightness, the cable glands are equipped with different
sealing inserts. They are available for the following cable diameters:
5.5 – 8.0; 8.0 - 10.5 and 10. – 13 mm.
Sealing insert and cable diameter must be aligned. Cable glands are only suited for lines with
a smooth surface.

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10 Limit switch setting
The limit switch setting defines the final limit positions OPEN and CLOSE.
Requirement
The door should open by pressing the OPEN
push-button of the control. If the door closes,
L1 and L2 must be swapped in a de-
energised state.
Setting of OPEN final limit position
Open to the desired OPEN final limit position
using the OPEN push-button.
Turn the cam of the S3 OPEN limit switch to
the centre of the switch plunger ①.
Tighten the screw of the cam ②.

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Check the door position:
Close the door ① until the cam is released
and open it again ② until the OPEN final limit
position is reached.
The OPEN final limit position can be
corrected by following the fine adjustment
procedure. Check the door position after each
correction.
The S1 EMERGENCY OPEN limit switch is preset by the setting of the OPEN final limit
position. The door must stop without posing any risks should the rotating direction be
incorrect or should there be a fault with the S3 OPEN limit switch. Follow the fine adjustment
procedure to correct the switching point of the limit switch as needed.
Setting of CLOSE final limit position and auxiliary limit switch
The same setting procedure applies as for setting the OPEN final limit position.

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11 Motor connection
G1 Bridge rectifier
DC-side switching
M1 Motor
R1 PTC thermistor
R2 PTC thermistor
R3 PTC thermistor
Y1 Spring applied brake
12 Limit switch connection
S10 Emergency manual operation
X12 Terminal strip
S1 Emergency OPEN limit switch
S2 Emergency CLOSE limit switch
S3 OPEN limit switch
S4 CLOSE limit switch
S5
A
dditional limit switch
S6
A
dditional limit switch