GFA ELEKTROMAT KE 80.24-55.00 User manual

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Installation Instructions
ELEKTROMAT
KE 80.24-55,00
Model: 10002539 10859
-en-
Status: 19.01.2022

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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Mechanical installation .................................................................................................... 7
4Electrical installation ..................................................................................................... 12
5Limit switch setting ........................................................................................................ 13
6Motor connection .......................................................................................................... 14
7Alternative motor connection ......................................................................................... 14
8Limit switch connection ................................................................................................. 15
9Emergency manual operation (hand chain operator) ..................................................... 16
10Completing commissioning / inspection ......................................................................... 18
11Disposal ........................................................................................................................ 20
12Declaration of incorporation / Declaration of conformity ................................................. 21

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. The force is transmitted using a
chain. Doors that must be secured against dropping require a separate safety brake.
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 24 rpm
Output torque 800 (640) 1) Nm
Output / hollow shaft 55,00 mm
Series SG 115 -
Limit switch range
(maximum revolutions of the output / hollow shaft)
60 -
Supply voltage 3~ 400 V
Operating current 4,70 A
Operating frequency 50 Hz
Power factor cos φ 0,77 -
Safety circuit 24 V
Degree of protection IP 65 -
Temperature range -10 / +40 (+60) 2) °C
Operating sound pressure level < 70 dB(A)
Maximum output speed OPEN / CLOSE
for frequency inverter operation
42 / 42 min-1
Cycles per hour 9 (2,7)1) h-1
Max. holding torque 800 Nm
Braking torque 20 Nm
Braking voltage 103-130 V DC
Rectifier type EGR 230/103 -
Manual force emergency manual operation 244 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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3Mechanical 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 BAGAB 00003_Z002
3 : 1
Permissible mounting positions

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Transmission elements
▶ Install the chain wheel
properly.
▶ Position the chain wheels
properly.
▶ Tighten the chain wheel
properly.
BAGAB00021_Z001
BAGAB00022_Z001

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Mounting
Four elongated holes are provided for mounting. Mount the supplied support angle on the
side of the sprocket.
B A GA D 04203_ Z001

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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 output-shaft.
BAGAE01201_Z001
▶ Install (①) and secure (②) the chain
wheel. Do not tighten yet. Install (③)and
secure (④) the output-shaft on the right or
left.

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▶ Mount the drive unit. Tighten the
connection elements to 170 Nm.
▶ Position the chain wheel (①) properly.
Install the chain wheel (②). Secure the
chain wheel (③).
▶ Tighten the chain wheel properly (①).
Tighten all connection elements (M16) to
170 Nm (②). Install all other connection
elements according to the specifications of
the door manufacturer.

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4Electrical 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.
BAH AA0 3 _ Z 0 0 1
BAHAC13_Z001
Completing the electrical installation
Mount the cable entries and/or cable glands.

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5Limit 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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6Motor connection
G1 Rectifier EGR
M1 Motor
X13 Motor plug
Y1 Spring applied brake
7Alternative motor connection
G1 Rectifier EGR
M1 Motor
X13 Motor plug
Y1 Spring applied brake

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8Limit switch connection
F10 Thermal contact
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

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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 Completing commissioning / inspection
Check the following components and then install all covers.
Gearbox
Check the drive unit for loss of oil (a few drops can be neglected). Protect the output-shaft
permanently against corrosion.
Mounting
Check that all connection elements (consoles, torque mounts, screws, locking rings, etc.) are
secure and in proper condition.
Electrical wiring
Check the connection cables and cabling for damage or crushing. Check that the screw
connections and plug connections are fitted properly with a good electric contact.
Emergency manual operation
Check the function with the power disconnected. Perform the check only between the final
limit positions.
Limit switch
Check the final limit positions by opening and closing fully. The safety area must not be
approached.

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Brake
Warning - Potential injury or danger to life!
Carry out a brake test. Overrun depends on the door and its equipment. The
specifications of the door manufacturer must be observed.
Brake lift may only be used in the final limit position CLOSE for doors that have no
counter-balancing.
Warning - Potential injury or danger to life!
Lifecycle brake - change complete brake unit at:
Operation with mains supply after 250.000 cycles
Operation with Inverter after 1.000.000 cycles
In an environment that can affect the coefficient of friction of the brake pad (atmosphere with
oil, solvents, detergents, etc.), class of protection IP65i must be adopted.
Drive unit
Note!
Engage a qualified engineer to check the drive unit annually
Apply shorter inspection intervals for doors that are operated frequently
Observe the applicable regulations and standards

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11 Disposal
Dispose of packaging
Dispose of the packaging material properly according to the local legal regulations or recycle
it.
Dispose of old devices
Dispose of old devices properly according to local legal regulations. Return old devices to the
return and collection systems available. You can also return GfA products free of charge.
Please apply enough postage to the package and mark it as "old devices".
Notice- Environmental damage!
The gearbox contains oil.
Ensure proper disposal according to local legal regulations.