GFA SI 80.12-55,00 Ex User manual

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Installation Instructions
ELEKTROMAT
SI 80.12-55,00 Ex
Model: 10002639 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 ..................................................................................................... 14
9Limit switch setting ........................................................................................................ 17
10Connection of the motor ................................................................................................ 19
11Limit switch connection ................................................................................................. 19
12Emergency manual operation (emergency hand crank) ................................................ 20
13Completion of commissioning / testing / operation ......................................................... 22
14Declaration of conformity, Motor .................................................................................... 27
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 T4 Gb
II 2D Ex tb h IIIC 130°C Db
Output torque 800 Nm
Output speed 12 rpm
Output / hollow shaft 55,00 mm
Locking torque 2800 Nm
Safety brake (testing centre / approval number) 14-003305-PR01
Maximum output speed Open / Close
for frequency inverter operation 12 rpm
Supply voltage 3~ 400 V
Operating current 2,70 A
Operating frequency 50 Hz
Power factor cos φ 0,76
Maximum movements per hour 12 h-1
Manual force, emergency manual operation 159 N
Protection class IP 65
Limit switch range
(maximum revolutions of the output / hollow shaft) 20
Temperature range -20 / +40 °C
Installation height < 1000 m
Components used
Gearbox SG 115F 123.T4
Motor F80-2GD CTVF /4
Terminal box 8146/1041
Limit switch / emergency manual operation switch 07-2511

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3Technical data of the gearbox
Series SG 115F-123.T4
Manufacturer GfA
Explosion protection II 2G Ex h IIC T4 Gb
II 2D Ex h IIIC 130°C Db
Max. output torque 800 Nm
Max. output speed 15 rpm
Shaft centre distance 115 mm
Transmission ratio 1:123
Temperature range -20 / +40 °C
Protection class IP 65

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4Technical data of the motor
Type F80-2GD CTVF C4
Manufacturer CEMP France
Explosion protection II 2G Ex d IIC T4
II 2D IP65 T 125°C
Certificate of verification TUV IT 14ATEX021X
Supply voltage 230 / 400 +/- 10% V
Operating current 4.68 / 2.70 A
Operating frequency 50 Hz
Power 1.1 kW
Power factor cos φ 0.76
Motor speed 1430 rpm
Motor torque 7.3 Nm
Operating mode S1
Protection class IP 65
Temperature class T4
PTC resistors 20°/140° 100-250 / 1600-4000 Ω
IA / IN ratio 4.9
Braking torque of spring-loaded brake 8 Nm
Braking voltage 205 V DC
Operating current of spring-loaded brake 0.12 A
Rectifier type B2-DC 230/205
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
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
Permissible mounting positions
+
BAGAC04005_Z001

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Warning – Explosion hazard!
 Check the atmosphere for explosion hazards before commencing installation tasks.
Mounting
2 elongated holes are provided for mounting (Ⓐ+Ⓑ).
▶ Installation in the vertical position is only permitted with an additional torque mount (Ⓑ).
BAGAD04005_Z001

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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.
BAGAE03003_Z002
▶ Mount the key.
BAGAE03004_Z001

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Variant Ⓐ:
▶ Attach the drive unit.
BAGAE4008_Z001
Variant Ⓐ:
▶ Tighten all connection elements (M16) with
a torque of 175 Nm. Install all further
connection elements according to the
specifications of the door manufacturer.
BAGAE04009_Z001
8.8
175 Nm
8.8
Variant Ⓑ:
▶ Lift the pedestal bearing (①). Mount the
torque mount (②+③). Do not yet tighten.

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Variant Ⓑ:
▶ Attach the drive unit.
BAGAE4010_Z001
Variant Ⓑ:
▶ Tighten all connection elements (M16) with
a torque of 175 Nm. Install all further
connection elements according to the
specifications of the door manufacturer.
BAGAE4011_Z001
175 Nm
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. 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.
Flameproof enclosure!
The motor cable gland must ensure that the flameproof enclosure is closed.
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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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
G1 Bridge rectifier
DC side
Switching
M1 Motor
R1 PTC resistor
R2 PTC resistor
R3 PTC resistor
Y1 Spring-loaded brake
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.