GFA 10004055 10004 User manual

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Installation Instructions
ELEKTROMAT
SI 180.12 FU-60,00
Model: 10004055 10004
-en-
Status: 07.02.2022

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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Integrated safety brake ................................................................................................... 7
4Mechanical installation .................................................................................................... 8
5Electrical installation ..................................................................................................... 13
6Limit switch setting ........................................................................................................ 14
7Motor connection .......................................................................................................... 15
8Limit switch connection ................................................................................................. 15
9Emergency manual operation (hand chain operator) ..................................................... 16
10Completion of commissioning / testing .......................................................................... 18
11Disposal ........................................................................................................................ 21
12Declaration of incorporation / Declaration of conformity ................................................. 22

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 vertically moving doors that need to 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 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 drive unit is
not intended for hazardous areas. 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.
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
instructions for the overall system. We recommend entering the danger area of the system
only when the drive unit is at a standstill.

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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 12 rpm
Output torque 1800 (1210) 1) Nm
Output / hollow shaft 60,00 mm
Series SG 115F -
Limit switch range
(maximum revolutions of the output / hollow shaft)
10 -
Supply voltage 3~ 380-460 V
Operating current 12,40 A
Operating frequency 50/60 Hz
Power factor cos φ 0,76 -
Safety circuit 24 V
Degree of protection IP 65 -
Temperature range +5 / +40 (+60) 2) °C
Operating sound pressure level < 70 dB(A)
Output speed OPEN 5-12 min-1
Output speed CLOSE 5-12 min-1
Output speed CLOSE > 2,5 m 5-12 min-1
Cycles per hour 10 (4,7)1) h-1
Max. holding torque 1800 Nm
Locking torque 3125 Nm
Safety brake (testing centre / approval number) 14-003305-PR01 -
Braking torque 20 / 5 Nm
Braking voltage 103 / 103 V DC
Rectifier type FU -
Manual force emergency manual operation 281 N
1) Specification in ( ) according to EN 60335-2-103.
2) When using a temperature range of +40°...+60°C use half of maximum cycles per hour.

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3Integrated 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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4Mechanical installation
Prerequisites
The permissible loads on walls, fastenings, mountings and transmission elements must not
be exceeded, even for maximum holding torques or locking torques (▶ refer to technical
data).
Connection elements
▶ Self-locking connection
elements with a minimum
strength of 800 N/mm2
(8.8) must be used.
▶ Utilize the hole diameter
to the full.
▶ Use adequately
dimensioned washers for
elongated holes.
BAGAB00002_Z002 BAGAB00003_Z002
3 : 1
Permissible mounting positions

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Mounting
Two elongated holes are provided for mounting (Ⓐ+Ⓑ).
▶ Vertical installation is possible only when an additional torque mount is used (Ⓑ).

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Installation
The descriptions below apply to general door specifications. The specifications of the door
manufacturer must also be observed during installation.
Warning - Potential injury or danger to life!
During installation, be sure to use a lifting device that has a sufficient load-
carrying capacity.
▶ Thoroughly grease the door shaft.
BAGAE03003_Z002
▶ Mount the keys.
BAGAE03004_Z001

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Version Ⓐ:
▶ Attach the drive unit.
Version Ⓐ:
▶ Tighten all connection elements (M16) to
175 Nm. Install all other connection
elements according to the specifications of
the door manufacturer.
Version Ⓑ:
▶ Raise the pedestal bearing (①). Install the
torque mount (②+③). Do not tighten yet.

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Version Ⓑ:
▶ Attach the drive unit.
Version Ⓑ:
▶ Tighten all connection elements (M16) to
175 Nm. Install all other connection
elements according to the specifications of
the door manufacturer.

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5Electrical installation
Warning - Danger to life from electric current!
Switch the mains OFF and check that the cables are de-energised
Observe the applicable regulations and standards
Make a proper electrical connection
Use suitable tools
Performing electrical installation
Remove the cover. Insert the motor plug. Insert the limit switch plug.
BAHEA03_Z001
BAHEB01_Z001 BAHEC01_Z001
Completing the electrical installation
Mount the cable entries and/or cable glands.

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6Limit switch setting
The setting of the final limit positions OPEN and CLOSE is described in the instructions for
the door control.
The door control must meet Performance Level c!
Use only door controls that evaluate the limit switch according to EN 12543 and meet
Performance Level c.

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7Motor connection
M1 Motor
X13 Motor plug
Y1 Spring applied brake
Y2 Spring applied brake
8Limit switch connection
BANA101101_Z001
S10
14
63
52 34
12
56
A
B
RS 485
A/D
MC
21
22
23
24
25
26
41
36
X12
W3 ws
br
gn
ge
gr
rsl
14
63
52 43
65
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S10 Emergency manual operation
X12 DES connection
1 Safety circuit
2 Channel B (RS485)
3 Ground
4 Channel A (RS485)
5 Safety circuit
6 Supply voltage
W3 Connection cable freqency inverter
(FI)

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9Emergency manual operation (hand chain operator)
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!
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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Switch on by pulling the red handle. Open or
close by pulling the chain. Switch off by
pulling the green handle.

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10 Completion of commissioning / testing
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.
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.
Mounting
Check all mounting elements (consoles, torque brackets, screws, retaining rings etc.) for
tightness and impeccable condition.
Electric wiring
Check connection cables and cables for damage or pinches. Check screw and plug
connections for correct seating and electrical contact.

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Emergency manual operation
Function to be checked in a de-energised state. Carry out functional test only between final
limit positions.
Limit switches
Check the final limit positions by opening and closing the door completely. The safety zone
must not be reached.
Brake
Warning – Injury or danger to life possible!
Carry out brake test. Overrun depends on the door and its equipment. The
manufacturer's specifications must be observed.
The brake release for doors without counter-balancing may only be used in the
CLOSE final limit position.
Warning – Injury or danger to life possible!
Service life of the brake - replacement of the entire brake in the case of:
Operation with mains supply after 250,000 door cycles
Operation with frequency inverter after 1,000,000 door cycles
Degree of protection IP65i must be used in environments that may change the friction
coefficient of the brake pad (atmospheres with oil, solvents, cleaning agents, etc.).

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Entire drive unit
Note!
Have the drive checked annually by a specialist.
Shorter inspection interval for frequently used doors.
Observe the applicable regulations and standards.