Motorline professional BRAVO500 Use and care manual

v4.0
REV. 04/2018
EN
USER'S AND INSTALLER'S MANUAL
EN
BRAVO500

2A 2B
2B
13A
13B
4A
4B
6A
12
5A
6A
7B
10B
9A
12
5B
7A
10A
8A
11
ENEN
INDEX STANDARDS TO FOLLOW
00. CONTENT 01. SAFETY INSTRUCTIONS
STANDARDS TO FOLLOW
SCHEMES FOR CAPACITORS
MAINTENANCE
INSIDE PACKAGE
OPEN COVER
INSTALLATION SITE PREPARATION
FINAL CONSUMERS INSTRUCTIONS
UNLOCK OPERATOR
SITE INSTALLATION – CREATE FOUNDATION
APPLICATION OF MOTOR
CLUTCH ADJUSTMENT
INSTALLATION OF NYLON GEAR RACK
SPECIALIZED TECHNICIANS INSTRUCTIONS
TECHNICAL SPECIFICATIONS
SITE INSTALLATION – EXISTING FOUNDATION
INSTALLATION OF PLATES THE LIMIT SWITCHES
INSTALLATION OF STEEL GEAR RACK
MAP OF INSTALLATION
01. SAFETY INSTRUCTIONS
06. COMPONENTS TEST
07. MAINTENANCE
02. PACKAGE
03. OPERATOR
04. INSTALLATION
05. TROUBLESHOOTING
This product is certified in accordance with European
Community (EC) safety standards.
This product complies with Directive 2011/65/EU of the
European Parliament and of the Council, of 8 June 2011, on
the restriction of the use of certain hazardous substances in
electrical and electronic equipment.
(Applicable in countries with recycling systems).
This marking on the product or literature indicates that the
product and electronic accessories (eg. Charger, USB cable,
electronic material, controls, etc.) should not be disposed of
as other household waste at the end of its useful life. To avoid
possible harm to the environment or human health resulting
from the uncontrolled disposal of waste, separate these items
from other types of waste and recycle them responsibly to
promote the sustainable reuse of material resources. Home
users should contact the dealer where they purchased this
product or the National Environment Agency for details on
where and how they can take these items for environmentally
safe recycling. Business users should contact their vendor and
check the terms and conditions of the purchase agreement.
This product and its electronic accessories should not be
mixed with other commercial waste.
Thismarkingindicatesthattheproductandelectronicaccessories
(eg. charger, USB cable, electronic material, controls, etc.) are
susceptible to electric shock by direct or indirect contact with
electricity. Be cautious when handling the product and observe
all safety procedures in this manual.
ENEN

3A 3B
ENEN
STANDARDS TO FOLLOWSTANDARDS TO FOLLOW
01. SAFETY INSTRUCTIONS01. SAFETY INSTRUCTIONS
ENEN
automated is in good mechanical condition, correctly balanced and opens
and closes properly.
• If the automation is to be installed at a level higher than 2,5 m above
ground level or other level of access, , should be followed the minimum
safety and health requirements for the use of work equipment workers
at work in Directive 2009/104/EC of the European Parliament and of the
Council of 16th September of 2009.
• In the case of the equipment where the automation will be installed, have
a pedestrian door, be aware that it must be closed when the automation is
activated.
• After installation, make sure that the mechanism is properly adjusted and
that the protection system and any manual unlocker works correctly.
• In order to protect the electrical cables against mechanical stress, you
should use conduit for the electrical wires, essentially on the power cable.
• When programming the control unit, pay particular attention to touching
only the location intended for that purpose. Failure to do so may result in
electric shock.
• It is important for your safety that these instructions are followed.
• Keep these instructions in a safe place for future reference.
• The ELECTROCELOS S.A. is not responsible for the improper use of the
product, or other use than that for which it was designed.
• The ELECTROCELOS S.A. is not responsible if safety standards were not
taken into account when installing the equipment, or for any deformation
that may occur.
• The ELECTROCELOS S.A. is not responsible for insecurity and malfunction
of the product when used with components that were not sold by the them.
• This product was designed and manufactured strictly for the use indicated
in this manual.
• Any other use not expressly indicated may damage the product and/or can
cause physical and property damages, and will void the warranty.
• Do not make any changes to the automation components and/or their
accessories.
• Keep remote controls away from children, to prevent the automated system
from being activated involuntarily.
• The customer shall not, under any circumstances, attempt to repair or tune
the automatism. Must call qualified technician only.
• The installer must have certified professional knowledge at the level of
mechanicalassembliesindoorsandgatesandcontrolboardprogrammation.
He should also be able to perform electrical connections in compliance
with all applicable regulations.
• The installer should inform the customer how to handle the product in an
emergency and provide him the manual.
• This device can be used by children 8 year old or older and persons whose
physical, sensory or mental capacities are reduced, or by persons without
experienceor knowledgeifthey havereceivedsupervision or instructions on
the use of the device in a safe manner and understood the hazards involved.
Children should not play with the device. Cleaning and maintenance by the
user must not be carried out by unsupervised children.
• Before installing, the installer must verify that the temperature range
indicatedontheautomatismis appropriateto the locationoftheinstallation.
• Before installing, the installer must verify that the equipment to be

4A 4B
385mm
226mm
380mm
01
04
05
A
A
A
03
02
02•
11•
10•
09•
04•
05•
03•
01•
08•
06•
07•
ENEN
Inside the package you will find the following components:
02. PACKAGE
INSIDE PACKAGE
01• 01 motor Bravo500
02• 02 release keys
03• 04 screws DIN912 M5x10
04• 04 fixing screws to the plate
05• 04 fixing screws to the ground
06• 01 fixation plate
07• 02 fixation plate of the limit switches
08• 01 user's manual
09• 02 photocells
10• 02 remote controls
11• 01 Control board
OPEN COVER
03. OPERATOR
During installation you will need
to open the motor cover, to access
various components on the inside.For
this, loosen the 2 screws identified
with (A) until the cover is free to be
removed.
Electronic components of the kit:
ENEN

5A 5B
255mm 144mm
145mm
329mm
271mm
36mm
183mm
186.5mm
319.5mm
06 07
09
10
08
76mm
ENEN
01 • Open the protection cover to acess
the key hole for the release.
03 • Pull the lever towards the outside, and you can now open/close the gate manually.
02 • Insert the key and turn it 90°.
03. OPERATOR 03. OPERATOR
TECHNICAL SPECIFICATIONSUNLOCK OPERATOR
To open manually the gate in case of electric power failure or in case of damage, follow
the below steps:
The specifications of the automatism BRAVO 500 are as follows:
The dimensions of automatism BRAVO 500 are the following:
So that the automation will operate normally, close the unlock and turn the key to the
original position. Close the cover (06) to finish, make a move in order to confirm the
functioning of the automation.
BRAVO500 BRAVO500/110
• Power Supply AC 230V 50Hz AC 110V 60Hz
• Power 280W 280W
• Current 0,8A 0,8A
• Speed 0,16 m/sec 0,16 m/sec
• Thermal protection 120ºC 120ºC
• Force 1200N 1200N
• Working temperature -25°C to 55°C >-25°C to 55°C
• Capacitor 8µF 25µF
• IP protection IP44 IP44
• Working frequency 25% 25%
• Noise level LpA <= 56 dB (A) LpA <= 56 dB (A)
• Thermal reset 2min to complete cycle 2min to complete cycle
• Maximum weight of leaf 500kg 500kg
• Maximum size of leaf 7m 7m
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6A 6B
295mm
529mm
60mm 60mm
11 16
14 15
17
12 13
ENEN
To ensure full operation of the automatism,pay attention the following recommendations:
• Read the entire manual at least once giving special attention to all notices marked
with ;
• Check that the gate structure is sufficiently resistant;
• The gate should be very well leveled and have a uniform movement without irregular
friction during the full course;
• The foundation to create in step 02 of page 4.B should be very resistant to support the
mounting screws of the plate;
• It is recommended that all locksmith works are carried out before proceeding with
installation of the automatism.
• Check if the size and weight of the gate correspond with the presented with the
technical data of the motor (p. 3B).
INSTALLATION SITE PREPARATION
INSTALLATION SITE PREPARATION
04. INSTALLATION 04. INSTALLATION
SITE INSTALLATION – CREATE FOUNDATION
NOTE:
For correct operation of the automatism,it is necessary to pay attention to the dimensions
given in the following images. Also check that the fixation plate is parallel to the gate.
01 • Make a hole in the ground to create a foundation in concrete. The dimensions
shown are these recommended to create the foundation. You must leave tubes in the
middle of the hole for the passage of cables for power and accessories, as shown in the
detail of image 11.
02 • Fill the hole with fresh concrete and
smooth the top part where you will fix the
plate.
03 • Attach the screws to the plate with
nut and counter nut as shown in picture
13.
04 • Insert the plate with screws in the concrete while it is still fresh and level it
horizontally with a level. Also align it parallel to the gate, keeping a distance of 60mm
between them, as visible in picture 16.
05 • Let the concrete dry so that the plate stays well fixed.
DETAIL 11
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7A 7B
18 19
21
22 23
20
28
60mm 60mm
63mm
24 25
26
27
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In case there is already a foundation at the installation site, proceed as below:
SITE INSTALLATION – EXISTING FOUNDATION APPLICATION OF MOTOR
04. INSTALLATION 04. INSTALLATION
01 • Place the fixing plate on top of the foundation and align it parallel to the gate, kee-
ping a distance of 60mm between them, as visible in Figure 19.
01 • Remove the side covers of the motor
by pulling them up.
02 • Place the motor in the fixing plate.
02 • Mark the place to make the holes for
the bushings. Must make the mark at the
center of the oval holes of the plate.
03 • Drill four holes with Ø18mm on foun-
dation. Place M10 steel anchors on the
holes.
03 • Align it parallel to the gate leaving a distance of 63mm between them, as visible in
the image 26. Oval holes of the motor should be centered with the threaded holes in the
fixing plate, as visible on DETAIL 26.
04 • Fix it with the M10 x 25 screws
provided.
05 • Reassemble the motor's side covers
to hide the screws.
04 • Place the fixing plate on the foundation in cement respecting the distances of
image 19. Use a level to levelit horizontally and fasten it with M10 screws.
DETAIL 26
ENEN

8A 8B
29
30 31
32 33
34
35 36
A
B
C
ENEN
04. INSTALLATION 04. INSTALLATION
INSTALLATION OF STEEL GEAR RACK
During the course of the gate, all elements of the rack must mesh properly with the
pinion (space 1.5mm)!
The spacers can't be welded to the rack! And also the pieces of rack with one another.
Do not use mass or other types of lubricant between rack and pinion!
INSTALLATION OF STEEL GEAR RACK
01 • Place spacers in all holes of the rack to fix it to the gate. Must put them in the
center of the oval holes in the rack, as shown in Figure 29, so you can adjust the rack at
the end of the installation if necessary.
02 • Place a piece of rack on top of the pi-
nion and level it horizontally with a level.
03 • Weld the spacer on top of the pinion.
04 • Close the gate a bit until the other end of the rack rests on top of the pinion and
weld the other spacer to the gate.
06 • Open the gate to support the point of
the new piece of rack on top of the pinion
and weld the spacer.
07 • Remove the piece of auxiliary rack
and open the gate until the other end
of the rack stands on top of the pinion.
Weld the spacer.
08 • Repeat the steps 5-7 for each meter of the rack, until you reach the end.
09 • Manually, test the movement of the gate with all racks already installed and weld
the remaining spacers. In case of finding some friction between the rack and pinion,
adjust the rack on the oval holes with screws.
05 • Close the gate a bit, so that the rack is not being supported on the pinion anymore
and apply another piece of rack (A). To synchronize the teeth with the piece already
installed, use an additional piece of rack (B) and place it under the union of the other
two, holding them with clamps (C).
Place the gate in the open position and unlock the motor! (p.03A). )
DETAIL 29
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9A 9B
37 38
39 40
41
42 43
A
B
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04. INSTALLATION 04. INSTALLATION
INSTALLATION OF NYLON GEAR RACK
During the course of the gate, all elements of the rack must mesh properly with the
pinion!
All rack supports must be weld at the gate.
Do not use mass or other types of lubricant between rack and pinion!
INSTALLATION OF NYLON GEAR RACK
Place the gate in the open position and unlock the motor! (p.03A)
01 • Place a piece of rack on top of the
pinion and level it horizontally with a level.
02 • Fasten the support of the rack over
the pinion to the gate.
03 • Close the gate a bit until the other end of the rack rests on top of the pinion and
fasten the other support.
05 • Open the gate until the other end of
the new rack is on top of the pinion rack
and fasten it to the gate.
06 • Open the gate until the other end
of the rack stands on top of the pinion.
Fasten it to the gate.
07 • Repeat the steps 4-6 for each rack piece until you reach the end.
04 • Close the gate a bit, so that the rack is not being supported on the pinion
anymore and apply another piece of rack (A), fitting it into the rack already installed
(B), as you can see in detail of image 41.
ENEN

10A 10B
1
2
3
44 45
46 47
48
49
ENEN
04. INSTALLATION
01 • Unbolt the screws and remove the
cover, as explained in p. 02B.
02 • You must now access the adjusting
screw of the clutch.
For this remove the cover of the control
board box. Loosen the 2 screws of the
control board and remove it from the box.
Now loosen the 2 screws that fix the box
of control board to the motor and remove
it as well.
03 • Adjust the screw in the upper part
of the motor. Use a 6mm hexagon key as
shown in image 49.
How to make the adjustment:
•Irreversibility of the motor.
Do a test to the motor’s irreversibility. For
that, just try to move the gate manually
with the motor locked. If the gate is
moving, it is necessary to adjust the screw
by rotating it clockwise (+).
•Idle speed of the motor
If the gate does not move at idle speed,
it means that the screw is too much
tightened. Rotate it counterclockwise
(-) until the motor moves the gate at idle
speed.
04. INSTALLATION
CLUTCH ADJUSTMENT
INSTALLATION OF PLATES THE LIMIT SWITCHES
01 • Place the opening limit-switch plate in the rack so that it can trigger the limit-
switch of the motor before the gate gets to opening stopper. The mechanical limit switch
is activated when the plate is in contact with the spring. The magnetic limit switch is
activated when the magnet is aligned with the motor reader (Fig. 45).
03 • Move the gate to the closed position
and repeat steps 1 and 2 to fix the closing
limit-switch plate to the rack.
02 • Put the DIN912 M5 x 12 screws supplied
with the accessories until the limit-switch
plate is fixed to the rack.
The tuning must achieve a balance between the gate's irreversibility and the
engines power.
Any adjustment must always be made lightly, always experimenting the motor's
operation with every adjustment until you achieve the necessary balance
between the irreversibility of the motor and the strength of idle speed.
To start the disassembly of the control board,disconnect the power and have
maximum care when handling it.
The limit-switch plates must be tuned for the gate stop before it hits the opening and
closing stoppers. Manualy test the activation of the limit-switches with the gate unlo-
cked, before you connect it to the electric power, in order to prevent problems due to
bad installation.
Place the gate in the open position and unlock the motor! (p.03A)
Mechanical limit switch
Mechanical limit switch
Mechanical limit switch
Mechanical limit switchMagnetic limit switch Magnetic limit switch
Magnetic limit switch Magnetic limit switch
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11
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04. INSTALLATION
MAP OF INSTALLATION
• FLASH LAMP • ANTENNA • CONTROL
BOARD
• BRAVO500 • PHOTOCELL • PHOTOCELL • KEY SELECTOR
LEGEND:
• Cables of connection
It is important to use stoppers on the opening and closing of the gate. If this is not
respected,there may be danger of the gate open too much in manual mode and jump
out of the rail.
It is important to use junction boxes for connections between motors,components
and control board. All cables enter and exit under the junction box and box of
control board.
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12
EN
SPECIALIZED TECHNICIANS INSTRUCTIONS
05. TROUBLESHOOTING
FINAL CONSUMERS INSTRUCTIONS
EN
SPECIALIZED TECHNICIANS INSTRUCTIONS
05. TROUBLESHOOTING
FINAL CONSUMERS INSTRUCTIONS
Problem Procedure Behavior Procedure II Discovering the origin of the problem
• Motor
doesn't work
• Make sure you
have 230V power
supply connected to
control board and if it
is working properly.
• Still not working • Consult a qualified
MOTORLINE technician.
• Motor
doesn’t move
but makes
noise
• Unlock motor and
move the gate by
hand to check for
mechanical problems
on the movement.
• Encountered
problems?
• Consult a qualified gates
technician.
1 • Check motion axis and associated motion systems related with the motor and the gate to find out what is the problem.
• The gate moves
easily?
• Consult a qualified
MOTORLINE technician.
• Motor opens
but doesn’t
close
• Unlock motor and
move the gate by hand
to closed position.
Lock motor again
and turn of power
supply for 5 seconds.
Reconnect it and send
order to open gate
using transmitter.
• Gate opened but
didn’t close again..
1 • Check if there is any
obstacle in front of the
photocells;
2 • Check if any of the control
devices (key selector, push
button, video intercom, etc.)
of the gate
are jammed and sending
permanent signal to control
unit;
3 • Consult a qualified
MOTORLINE technician.
• Gate doesn’t
make
complete
route
• Unlock motor and
move gate by hand to
check for mechanical
problems on the gate.
• Encountered
problems?
• Consult a qualified gates
technician.
1 • Check all motion axis and associated motion systems related with the gate to find out what is the problem.
• The gate moves
easily?
• Consult a qualified
MOTORLINE technician.
1 • Open control board and check
if it has 230V power supply;
2 • Check input fuses of the
control board;
3 • Disconnect the motor from
control board and test them by
connecting directly to power
supply in order to find out if they
have problems (see page 11A).
4 • If the motor works, problem is
on the control board.
Pull it out and send it to our
MOTORLINE technical services
for diagnosis;
5 • If the motor doesn’t work,
remove them from installation
site and send to our MOTORLINE
technical services for diagnosis.
1 • Check capacitor, testing
operator with a new one;
2 • If capacitors are not the
problem, disconnect motor from
control board and it them by
connecting directly to power
supply in order to find out if it has
problems (see page 11A);
3 • If the motor works, the
problem is from control board.
Pull it out and send it to our
MOTORLINE technical services
for diagnosis;
4 • If the motor doesn’t work,
remove them from installation
site and send to our MOTORLINE
technical services for diagnosis.
1 • Check capacitors, testing with
new capacitors.
2 • If capacitors are not the
problem, disconnect motor
from control board and test it
by connecting directly to power
supply in order to find out if it is
broken;
3 • f the motor doesn’t work,
remove it from installation site
and send to our MOTORLINE
technical services for diagnosis.
4 • If motor work well and move
gate at full force during the
entire course, the problem is
from controller. Set force using
trimmer on the board. Make a
new working time programming,
giving sufficient time for opening
and closing with appropriate
force .
5 • If this doesn’t work, remove
control unit and send it to
MOTORLINE technical services.
NOTA: Setting force of the
controller should be sufficient
to make the gate open and close
without stopping, but should stop
and invert with a little effort from
a person.
In case of safety systems failure,
the gate shall never cause
physical damaged to obstacles
(vehicles, people, etc).
All MOTORLINE control boards have LEDs that
easily allow to conclude which devices are
with anomalies.
All safety devices LEDs (DS) in normal
situations remain On.
All "START" circuits LEDs in normal situations
remain Off
If LEDs devices are not all On, there is some
security systems malfunction (photocells,
safety edges), etc.
If "START" circuits LEDs are turn On, there is a
control device sending permanent signal
A) SECURITY SYSTEMS:
1 • Close with a shunt all safety systems
on the control board (check manual of the
control board in question).
If the automated system starts working
normally check for the problematic device.
2 • Remove one shunt at a time until you find
the malfunction device.
3 • Replace it for a functional device and
check if the motor works correctly with all
the other devices. If you find another one
defective, follow the same steps until you find
all the problems.
B) START SYSTEMS:
1 • Disconnect all wires from START terminal
input.
2 • If the LED turned Off, try reconnecting one
device at a time until you find the defective
device.
NOTE:
In case procedures described in sections A)
and B) don’t result, remove control board and
send to our technical services for diagnosis;

13A 13B
50
51
52
ENEN
• Check all screws of the automation
such as the fixing plate to the ground,
the plates of the limit switches, motor
and the gear rack.
•Check that the distance between rack
and motor remains unchanged and this
engages the teeth of the pinion of the
engine correctly (over time can happen
some distortion).
•Lubricate all systems/axis of movement
of the gate. Lightly lubricate with spray
the rack and pinion.
06. COMPONENTS TEST 07. MAINTENANCE
SCHEMES FOR CAPACITORS MAINTENANCE
All tests must be performed by skilled technicians due to serious danger associated
with the misuse of electrical systems!!
These maintenance measures must be made every 6 months to maintain the good
functioning of the automatism.
AUTOMATISM
8μF
Capacitor
1
2
3
2
COM 1
COM 2
COM
Ground Wire
Phase 2
Phase 1
Open
Close
Motor
Power Supply 1
Power Supply 2
To detect if the malfunction is on the control board or on the motor is, sometimes,
necessary to perform tests with connection directly to a 110V/230V power supply.
For this, it is necessary to interpose a capacitor on the connection in order to the
automatism to work (check the type of capacitor to be used in the product manual).
The diagram below, shows how to make that connection and how to merge the different
components wires.
01 • Connect the power wires to the terminal, as shown below.
02 • Connect the automatism wires in the terminal, interposing a capacitor in the
opening and closing wires.
03 • Once these connections are completed, connect to a 110V/230V power outlet,
depending on the motor / control board in test.
NOTES:
> To perform the tests, there is no need to remove the automatism from the place it is instal-
led, because in this way, it is possible to understand if the automatism can function properly
connected directly to the current.
> You should use a new capacitor during this test to ensure that the problem does not lie on
it.
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