GFA ELEKTROMAT SI 40.15-40,00 Ex User manual

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Installation Instructions
ELEKTROMAT
SI 40.15-40,00 Ex
Model: 10002591 00001
-en-
Status: 22.11.2019

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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 of the drive unit ....................................................................................... 5
3Technical data of the gearbox ......................................................................................... 6
4Technical data of the motor ............................................................................................. 7
5Technical data of the terminal box ................................................................................... 8
6Technical data of limit switch / emergency manual operation switch ............................... 8
7Mechanical installation .................................................................................................... 9
8Electrical installation ..................................................................................................... 13
9Limit switch setting ........................................................................................................ 15
10Connection of the motor ................................................................................................ 17
11Limit switch connection ................................................................................................. 17
12Emergency manual operation (emergency hand crank) ................................................ 18
13Completion of commissioning / testing / operation ......................................................... 20
14Declaration of conformity, Motor .................................................................................... 24
15Declaration of conformity, Accessories .......................................................................... 28
16Declaration of incorporation / Declaration of conformity ................................................. 30

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 normal use
The drive unit is intended for doors, which have to be secured against falling down. A safety
brake is integrated in the gearbox. The drive unit is mounted directly onto the shaft. In
compliance with its explosion protection according to ATEX 2014/34/EU, it may be used in
explosive areas.
The safe operation is only guaranteed with specified normal use. The drive unit is to be
protected from rain, moisture and aggressive ambient conditions. No liability for damage
caused by other applications or non-observance of the information in the manual.
Modifications are only permitted with the agreement of the manufacturer. Otherwise the
Manufacturer’s Declaration shall be rendered null and void.
Safety information
Installation and initial operation tasks are to be performed by skilled personnel only.
Only trained electrical craftsmen are permitted to work on electrical equipment. They must
assess the tasks assigned to them, recognise potential danger zones and be able to take
appropriate safety measures.
Installation work is only to be carried out with the supply off and in a non-explosive
atmosphere.
Observe the applicable regulations and standards.
Documentation
The drive unit consists of components according to ATEX 2014/34/EU which are reliably
assembled. The documentation refers to the safe installation and operation of the drive unit.
It only quotes excerpts from the original documentation of the components. Should you have
any questions, please contact the manufacturer of the component.
Coverings and protective devices
Do not operate unless corresponding coverings and protective devices are installed.
Ensure that gaskets are fitted correctly and that cable glands are correctly tightened.
Spare parts
Only use original spare parts.

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2Technical data of the drive unit
Explosion protection II 2G Ex db eb ib h IIC T3 Gb
II 2D Ex tb h IIIC 190°C Db
Output torque 400 Nm
Output speed 15 rpm
Output / hollow shaft 40,00 mm
Locking torque 760 Nm
Safety brake (testing centre / approval number) 14-003612-PR03
Supply voltage 3~ 400 V
Operating current 2,60 A
Operating frequency 50 Hz
Power factor cos φ 0,80
Maximum movements per hour 16 h-1
Manual force, emergency manual operation 136 N
Protection class IP 65
Limit switch range
(maximum revolutions of the output / hollow shaft) 20
Temperature range -10 / +40 °C
Installation height < 1000 m
Components used
Gearbox SG 85F 92.T3
Motor U/ENFY 80/4O-13S
Terminal box 8146/1041
Limit switch / emergency manual operation switch 07-2511

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3Technical data of the gearbox
Series SG 85F-92.T3
Manufacturer GfA
Explosion protection II 2G Ex h IIC T3 Gb
II 2D Ex h IIIC 190°C Db
Max. output torque 400 Nm
Max. output speed 19 rpm
Shaft centre distance 85 mm
Transmission ratio 1:92
Temperature range -10 / +40 °C
Protection class IP 65

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4Technical data of the motor
Type U/ENFY 80/4O-13S
Manufacturer ATB Motorenwerke GmbH
Explosion protection II 2G Ex e IIC T3 Gb
II 2D Ex tb IIIC T 120°C Db
Certificate of verification PTB 00 ATEX 3232/38
PTB 00 ATEX 3232/40
Supply voltage 230 / 400 +/- 5 % V
Operating current 4.5 / 2.6 A
Operating frequency 50 Hz
Power 1.1 kW
Power factor cos φ 0.80
Motor speed 1415 rpm
Motor torque 7.5 Nm
Operating mode S1
Protection class IP 65
Temperature class (G)
Temperature class (D) T3 T 120 °C
Heating time tE (G)
Heating time tE (D) 14 19 s
IA / IN ratio 5.2
Temperature range -20 / + 40 °C

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5Technical data of the terminal box
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
Protection class IP 66
6Technical data of limit switch / emergency manual operation switch
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
Protection class IP 66
Attention – Damage to components!
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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7Mechanical 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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8Electrical 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.
The excess current setting must be selected such that the motor is disconnected from the
mains within the heating time tE. The actual tripping time tA at a relative operating current of IA
/ IN must be calculated on the basis of the tripping characteristic of the excess current relay. It
must be ensured that tA < tE is given.
Completing the electrical installation
Install cable entries and/or cable glands.

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9Limit 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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10 Connection of the motor
M1 Motor
11 Limit switch connection
S10 Manual operation
X12 Terminal rail
S1 Safety open limit switch
S2 Safety close limit switch
S3 Open limit switch
S4 Close limit switch
S5 Additional limit switch
S6 Additional limit switch

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12 Emergency manual operation (emergency hand crank)
The emergency manual operation is designed for opening or closing the door without power
supply. Its activation interrupts the control voltage. Electrical operation is no longer possible.
Warning – Injuries due to incorrect operation or falling objects!
Switch off voltage.
Adopt a secure position.
For drive units with brake, the emergency manual operation must be carried out
against the closed brake.
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.
Caution – Damage to components!
Do not move the door beyond the final limit positions.

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Plug in the crank and turn until it engages
(①). Open or close by turning the crank (②).
After use, the crank may be attached to the
drive unit.
▶ Attach as illustrated.

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13 Completion of commissioning / testing / operation
Check the following components and after that, mount all covers.
Gearbox
Check drive unit for oil loss (a few drops are not critical). Protect output shaft permanently
against corrosion.
Oil leakage!
Oil leakage may render explosion protection ineffective. Oil maintenance is
inadmissible.
Safety brake in the gearbox
The safety brake requires no maintenance or inspection.
Warning – Danger of the door dropping
In the case of a gearbox damage, the internal safety brake is triggered to prevent the
door from dropping. The gearbox stalls.
Releasing the stalling may cause the door to drop!
Block the door for pedestrians and vehicles.
Do not release the stalling. Do not use the emergency manual operation.
Secure the door against dropping. Please observe the specifications of the door
manufacturer.
The drive unit needs replacement. Please observe the specifications of the door
manufacturer.
Motor
Check motor for defective bearings.