Novoferm NovoZip User manual

EN
Installation Manual
Self-Repairing High-Speed Door - NovoZip
V03 - 09-2020

Installation Manual
NovoZip
English
Nr. Date Prepared by Checked by Approved by Comments
00 06-11-2018 P.H.M. H.A.L. I.L.T.
01 20-12-2018 P.H.M. H.A.L. I.L.T.
02 14-01-2019 P.H.M. H.A.L. I.L.T.
03 05-08-2019 H.A.L. H.A.L. I.L.T.
04 22-01-2020 H.A.L. H.A.L. I.L.T.
REVISIONS TABLE

EN
1
Contents
1. PURPOSE / SCOPE 2
2. REGULATIONS 2
3. INSTALLERS 2
4. INSTALLATION 3
4.A. Important warnings 3
4.B. Elements that make up the kit. 4
4.C. List of tools and equipment
required for assembly 4
4.D. Pre-assembly steps 5
4.D.1. Arrival at the work site 5
4.D.2. Unloading of materials 5
4.E. Door assembly 6
4.E.1. Component diagram 6
4.E.2. Initial checks 7
4.E.3. Door placement 9
4.E.4. Release operation 15
4.E.4.a. Crank drive 15
4.E.4.b. Chain drive (option) 16
4.E.5. Technical characteristics of the motor. 17
4.E.6. Technical characteristics
of the control panel. 19
4.E.7. Installation of accessories 20
4.E.8. Final checks 20
This installation manual must be handed to the customer and must be kept in a safe place throughout the whole period of use!

EN
2This installation manual must be handed to the customer and must be kept in a safe place throughout the whole period of use!
1. PURPOSE / SCOPE
This instruction manual details the components and steps to follow during the installation when carried out by
the manufacturer or when carried out under its responsibility, as well as the installation of the door in cases in
which it is supplied by Novoferm as a complete kit, and when this installation is carried out by an installer chosen
by the user. The risks related to the installation are also set out. Installations in which components not supplied
by NOVOFERM are used do not fall within the scope of this document.
Only the correct installation and maintenance, carried out by a competent organisation or person, in accordance
with the instructions given in this manual, can ensure the safe installation, operation and use (including
maintenance and repair) of an industrial door used for the transport of vehicles and persons.
Please read these operating instructions carefully and comply with all contents and safety instructions.
The instructions in this manual cannot, by themselves, make the work safe and do not preclude the operator from
observing the safety code or local or national law, rules or regulations.
The images and diagrams are generic and therefore this information may vary due to constant research and
development by NFA.
2. REGULATIONS
During the installation of the door, the following regulations must be observed:
• European Construction Products Regulation (EU) No. 305/2011.
• Machinery Directive (2006/42/EC).
• Low Voltage Directive (2014/35/EU)
• Electromagnetic Compatibility Directive (2014/30/EC)
• Radio Equipment Directive (2014/53/EU)
• EN 13241:2016. Industrial, commercial garage doors and gates. Product standard. Part 1: Products without
fire resistance or smoke control characteristics.
• EN ISO 12100:2012. Machinery safety General design principles. Risk assessment and risk reduction.
• EN 614-1:2006+A1:2009. Machinery safety Ergonomic design principles. Part 1: Terminology and general
principles.
• EN 12433-1:2000. Industrial, commercial garage doors and gates. Terminology. Part 1: Types of doors.
• EN 12433-2:2000. Industrial, commercial garage doors and gates. Terminology. Part 2: Door components.
• EN 12453:2001. Industrial, commercial garage doors and gates. Safety in the use of motorized doors.
Requirements.
• EN 12604:2000. Industrial, commercial garage doors and gates. Mechanical aspects. Requirements
3. INSTALLERS
This manual is intended for professional installers only, meaning those persons or organisations that provide door
installation and improvement services to third parties.
Professional installers must have at their disposal competent persons, adequately trained, qualified in their
knowledge and practical experience, and must be in possession of this instruction manual in order to enable them
to carry out the installation correctly and safely. Partially trained personnel will only be used as assistants under
the supervision of the installer.
These competent persons must update their skills and knowledge in line with the emergence of new techniques
and product developments, and the professional installer shall keep training records. They shall also have the
ability to verify conformity with European standards EN 12604 and EN 12453.

EN
3
This installation manual must be handed to the customer and must be kept in a safe place throughout the whole period of use!
4. INSTALLATION
4.A. Important warnings
The contents of this manual must be read completely before assembly. For the safe assembly and use of the door,
we recommend that you follow the instructions in this manual carefully. After completing the assembly and
checking the installed product, the user will be informed about the methods of use and the risks associated with
the use of the door.
Assembly, electrical connections and regulations must be carried out by qualified personnel in compliance with
the standards in force and according to the instructions given.
Work on the industrial door should only be carried out when the door is not in operation.
The components are made of high quality, sustainable and durable materials. However, during installation all
necessary precautions must be taken to avoid damage.
Defective parts must always be replaced with original parts, otherwise the safe and proper functioning of the door
cannot be guaranteed and there is a risk that the warranty will be invalidated.
The software of the programmable control panel must not be modified. Only the supplier will be able to modify or
add anything to the product.
The motor must be used exclusively for the purpose for which it was designed. Any other use should be considered
inappropriate and therefore dangerous.
The safety devices (photocells, light curtain, etc.) must be installed in compliance with the standards in force, as
well as the installation environment, the operation of the system, and the force exerted by the door. Safety devices
must protect the entire area of the door’s trajectory in order to prevent entrapment or shearing.
The electrical installation establishes the execution and commissioning of the electrical installations, which must
only be carried out by authorised installers, in accordance with local and/or national regulations, and the
appropriate technical documentation must be provided.
If in doubt, request assistance from qualified personnel.
After the installation is completed, the correct operation of the door will be verified by filling in the corresponding
register that certifies such verifications.
For any information or interpretation regarding that set out in this manual, do not hesitate to contact the technical
support service:
Novoferm Nederland BV
 088-8888112
 www.novoferm.nl
ATTENTION:
• During installation there is a risk that components will fall, which may cause injury to persons or
damage to objects.
• There is a risk of electrocution if there is contact with the mains voltage. Make sure that the electrical
installation on the client‘s premises meets the applicable safety requirements.
• During all work on the doors, make sure that the power is not connected and protect it against
unauthorised use.
• Only carry out welding and grinding work when this is expressly permitted. Be careful, since there may
be a risk of fire or explosion. Ensure that there is sufficient ventilation for welding or grinding, as dust
and other flammable substances may pose a risk of explosion.

EN
4This installation manual must be handed to the customer and must be kept in a safe place throughout the whole period of use!
4.B. Elements that make up the kit
The door assembly kit consists of the elements detailed below:
• Metal side frames.
• Flags.
• Plastic side guides.
• Zipper guides.
• Bearings.
• Motor supports.
• Pulley.
• Protective covers.
• Canvas: Made of PVC coated polyester with side zippers.
• Upper spacer.
• Brush.
• Motor.
• Control panel.
• Photocell. / reflector
• Light curtain.
• Hardware bag.
• Documentation: Use and maintenance manuals
4.C. List of tools and equipment required for assembly
The following is a list of tools required for the assembly and commissioning of the door, NOVOFERM assembly
equipment:
• Truck-Mounted Crane. Reach truck or forklift
• Lead wire, coloured tracing wire, markers, pencils, level and crossbar.
• Manual electrode welding machine.
• Drilling machine with drill bits for steel ø 6, 8, 10, 12, 14, 15
• Percussion drill with bits ø 6, 8, 10, 12, 14, 15.
• Screwdriver.
• Grinder.
• Tool box composed of: hammer, set of screwdrivers with star or flat head, set of hexagonal wrenches, locking
pliers (at least two), normal pliers, pincers, 6, 8, 10, 12, 13, 14, 17, 24 fixed spanners, sheet shears, flat and
round file, 5 m metre, gauge.
• Construction clamps.
• Grip wrenches
• Extensions with socket and plug according to EEC standards, for 230 v.
• Extension with socket and plug according to EEC standards, for 380 v.
• 230v mobile adapters for industrial power outlet and personal power outlet.
• Rolling scaffolding according to the standard adapted to the dimensions of the door to be installed.
• Ladder (2 - 6 m).
• Set of adapted plugs with dimensions suitable for the type of structure.
• Self-tapping and self-drilling screws.
• Mechanical fixing bolts.
• Metal slings and straps.
• Safety equipment: Work clothes, safety boots, ear protection, thick canvas gloves, high visibility vest, goggles,
helmet and everything needed to prevent and signal hazards in the workplace.

EN
5
This installation manual must be handed to the customer and must be kept in a safe place throughout the whole period of use!
4.D. Pre-assembly steps
4.D.1. Arrival at the work site
The safety helmet will be worn at all times on the work site to protect against possible falling objects. Boots
should also be worn with the sole protected against sharp elements and the upper area of the toes protected with
metal reinforcements to avoid damage caused by blows and crushing from falling heavy material.
When arriving at the work site, contact the client or representative, verify that the space where the door will be
placed is tidy and free of obstacles, and supervise the site indicated for the unloading of the material. The site
intended for the storage of material shall be as close to the opening as possible.
Ensure that a three-phase and/or single-phase power supply is available.
4.D.2. Unloading of materials
When unloading material, weight less than or equal to 50 kg will be unloaded manually by two operators, while a
boom or crane will be used for unloading weights over 50 kg.
ATTENTION: Installers must strictly comply with the rules on safety in the workplace, on the work site and
the safety of the installations.
ATTENTION: All terms set out here with regard to safety are general terms. Along with this manual, you
should always have available the manual for the prevention of occupational hazards, which provides more
detailed information on safety measures.
Mandatory
head protection
Mandatory
foot protection
Mandatory
hand protection
Mandatory
body protection
Mandatory head protection Mandatory foot protection

EN
6This installation manual must be handed to the customer and must be kept in a safe place throughout the whole period of use!
• The top covers, pulley, spacer, and side frames can be easily handled and transported by forklift or pallet
truck, or by hand by several people depending on the weight (variable depending on the model and size of the
door).
• The canvas shall be handled with care so as not to damage its surface or profiles. Methods according to
weight shall be used for their displacement.
• The rest of the elements that compose the kit are easily handled manually.
For the distribution and storage of material the following will be taken into account:
• Place the materials as close as possible to the opening, in a safe location where there is no risk that they will
fall or become deformed.
• Place the materials in areas protected from the weather and away from dust-generating machines.
• Keep the transit areas free.
4.E. Door assembly
Figure 1 - Main components of the NovoZip high-speed door
4.E.1. Component diagram

EN
7
This installation manual must be handed to the customer and must be kept in a safe place throughout the whole period of use!
L
4.E.2. Initial checks
The following aspects should be checked before assembly:
• Check that the door has not been damaged in any way that could compromise its installation or operational
safety. The aim is to check that all the packaging material is intact.
• Verify that the material received matches that detailed in section 4.B of this document, counting and checking
it item by item.
• Check that the information given in the assembly order is correct, primarily:
• Check that the dimensions of the opening, width and diagonal measurements, are exact and conform to the
dimensions of the door.
L= width of the opening
H = height of the opening
h = lintel height = 500 mm
D = diagonal
SX = left side clearance
(standard motor side) = 310 mm
DX = right lateral space = 110 mm
A = Lintel width = 320 mm
No. Item No. Item No. Item
01 Right lateral frame
with plastic guide 07 Canvas with side zippers 13 Motor support
02 Left lateral frame
with plastic guide 08 Control panel 14 Mounting bracket
03 Pulley 09 Upper spacer 15 Key
04 Flag 10 Brush 16 Roll cover
05 Bearings 11 Photocell 17 Motor cover
06 Motor 12 Light curtain 18 Right side cover
Figure 2 - Required right-left lateral space and lintel of the opening
H+h
H
SX
DX L
DX+L+SX
h
A

EN
8This installation manual must be handed to the customer and must be kept in a safe place throughout the whole period of use!
• Make sure that the floor on which the pre-assembly is to be carried out is smooth and has the right
dimensions for the door to be placed horizontally. Check that the floor where the door is to be assembled is
level and clean.
• Check whether the building materials of the opening in which the door is to be installed are concrete/brick or
metal. This information will determine the system for fixing the door to the opening. In both cases the
mooring points will be defined by the mooring holes previously drilled in the guides.
• Avoid installing the door in places where its use and duration are incompatible with the materials used to
manufacture it. (e.g. Strongly corrosive environment). If in doubt, please contact Novoferm.
• The installation of the door while children are present, or in any case while in the presence of persons not
related to the assembly work, is forbidden. We recommend that the assembly be carried out by qualified
installers.
Before connecting the motor, check that:
• The data on the motor plate is compatible with the mains data.
• The product is connected to an efficient earthing system.
• A differential switch has been installed on the panel that controls the motor.
• Apply the signs provided for by current regulations to identify hazardous areas.
• Before connecting the power supply, check that the installed power is greater than that required by the au-
tomated system.
• Carry out the earthing according to the safety regulations in force.
• The installer must inform the user about the automatic and manual emergency operation of the door and
give him/her the instructions for use.
• The manufacturer cannot be held responsible for any damage caused as a result of failure to comply with
these rules.
ATTENTION: The company is not responsible for the installation not being earthed or the lack of
differential switch.

EN
9
This installation manual must be handed to the customer and must be kept in a safe place throughout the whole period of use!
4.E.3. Door placement
• Proceed to screw between the flag and its respective side frame.
Figure 3 - Flag joint with side frame
Mandatory
head protection
Mandatory
foot protection
Mandatory
hand protection
Mandatory
eye protection
Mandatory
hearing protection
Mandatory
body protection

EN
10 This installation manual must be handed to the customer and must be kept in a safe place throughout the whole period of use!
Figure 4 - Screwing of the pulley assembly.
The pulley assembly (pulley, bearings, motor support, motor and retracted canvas) is then attached to each of the
flags.
GFA TS971 Control
Standard drive
Tormatic Control
Left (option)
SG63F SI 8.180-25,40 drive
Tormatic Control
Right (option)
SG63F SI 8.180-25,40
drive
ATTENTION: This operation involves the upper spacer, whose function is to ensure the required design
distance between the two sets formed by the frame and flag.
6 mm Spacer
* Extra
M8x30 Motor support
Upper spacer
Flag
Pulley assembly
* Extra: Only with a Tormatic Control
on the right side, extra 6 mm spacers
must be placed between the motor
support and the drive.
Spring washer M8
M8x30

EN
11
This installation manual must be handed to the customer and must be kept in a safe place throughout the whole period of use!
• The side frames are lifted with the pulley assembly and presented in the hole where they are to be mounted.
Figure 6 - Levelling and plumbing of the side frames with the flags.
• The frames and pulley assembly are levelled and flattened to ensure that the frames with the flags are at the
same height and that they are in position.
Figure 5 - Presentation of the side frames with the pulley assembly.

EN
12 This installation manual must be handed to the customer and must be kept in a safe place throughout the whole period of use!
Figure 7 - Fixing the assembly to the wall and floor
• Mounting:
If the opening is made of concrete/brick, the fastening will be achieved using a plastic plug and a coach screw,
or a 10x60 mm metal plug.
If the opening has a metal pre-frame, the fastening will be carried out with M8 screws of variable length
depending on the dimensions of the metal pre-frame.
In both cases the mooring points will be defined by the mooring holes previously drilled in the side frames.
There are also two brackets that must be screwed to the frames to fix them to the floor.

EN
13
This installation manual must be handed to the customer and must be kept in a safe place throughout the whole period of use!
• Once we have screwed the assembly to the wall, we are ready to screw the outside of the side frame, as shown
in the picture.
Figure 8 - Fastening of the outside of the side frames

EN
14 This installation manual must be handed to the customer and must be kept in a safe place throughout the whole period of use!
Figure 10 - Application of the glue to the zipper
• The first section of the zipper canvas (between 2 and 4 teeth) must be stiffened by applying the special glue
to help it descend.
Figure 9 - Mounting of the roll cover and motor cover
• The roll cover is screwed onto the flags and then the motor cover.

EN
15
This installation manual must be handed to the customer and must be kept in a safe place throughout the whole period of use!
ATTENTION: the motor, the control panel, and the safety devices are supplied with their corresponding
installation, user and maintenance manuals. Please read the relevant manual carefully before installation.
• Connect the motor to the control panel. See section 4.E.5
• Connect the control panel to the main power supply.
• Check the direction of rotation of the motor using the open and close buttons. If it is not correct, change two
of the phases in the absence of current.
• Programme the control panel according to the instructions. See section 4.E.6
• Limit switch setting OPEN.
• Limit switch setting CLOSE.
• Connect the various accessories (photocell, light curtain, signals, etc.), following the instructions in the
accessory‘s manual.
• Check the perfect operation of the drive and the effective efficiency of the control panel, safety devices, etc.
Figure 11 - Detail of the crank release system
• After finishing the manual operation, the crank is removed and returned to its original position. This also puts
the electrical system of the motor back into operation.
ATTENTION: Reconnect the shaft brake before releasing the crank. If this is not done, the door will close
abruptly.
4.E.4 Release operation
Depending on the characteristics of the door, there are two possibilities for manual operation if necessary:
4.E.4.a Crank drive
Once it has been checked that the door cannot be operated, the following steps must be taken:
• Remove the crank from its holder and insert it into the designated housing, turning it as far as it will go (1).
When performing this operation, the control phase is interrupted and the electric drive of the door is also
non-operational.
• Apply the shaft brake lever to release the shaft and make the door easier to open
• Open the door manually by turning the handle (2). The shaft brake must be kept free during this manoeuvre.

EN
16 This installation manual must be handed to the customer and must be kept in a safe place throughout the whole period of use!
4.E.4.b Chain drive (option)
Once it has been checked that the door cannot be
operated, the following steps must be taken:
• Pull the red handle to activate the release system.
When performing this operation the electric door
drive is switched off.
• Pull the chain to open or close the door manually.
• Pull the green handle to deactivate the release
system. This causes the electrical system of the
motor to start up again.
ATTENTION: Under no circumstances should the door be unlocked without first disconnecting the power supply.
Figure 12 - Detail of the chain release system

EN
17
This installation manual must be handed to the customer and must be kept in a safe place throughout the whole period of use!
4.E.5 Technical characteristics of the motor.
The door in standard configuration will be equipped with one of the two following motorization options:
SI 3.5 350 FU
Output torque 35 Nm
Number of output revolutions OPENING 30 - 350 rpm
Number of output revolutions CLOSING 30 - 100 rpm
Number of output revolutions CLOSING > 2.5 m 30 - 150 rpm
Drive shaft / hollow shaft 25 mm
Fall time 510 Nm
Parachute system (test point/certificate number) 14-003612-PR02
Maximum stop time 90 Nm
Operating voltage 1~ 230 V
Working current 6,60 A
Operating frequency 50 Hz
Power factor cos φ 0,47
Maximum connections per hour 66 h-1
Manual force emergency operation 140 N
Type of protection IP 65
Limit switch area
(maximum speed of the drive shaft / hollow shaft) 20
Braking torque of the brake 9 Nm
Braking voltage 103 VCC
Type of rectifier FU
Temperature range +5 / +40 °C

EN
18 This installation manual must be handed to the customer and must be kept in a safe place throughout the whole period of use!
SI 5 250 FU
Output torque 50 Nm
Number of output revolutions OPENING 30 - 250 rpm
Number of output revolutions CLOSING 30 - 100 rpm
Number of output revolutions CLOSING > 2.5 m 30 - 150 rpm
Drive shaft / hollow shaft 25,40 mm
Fall time 510 Nm
Parachute system (test point/certificate number) 14-003612-PR02
Maximum stop time 90 Nm
Operating voltage 1N~ 230 V
Working current 6,60 A
Operating frequency 50 Hz
Power factor cos φ 0,47
Maximum connections per hour 66 h-1
Manual force emergency operation 199 N
Type of protection IP 65
Limit switch area
(maximum speed of the drive shaft / hollow shaft) 20
Braking torque of the brake 9 Nm
Braking voltage 103 VCC
Type of rectifier FU
Temperature range +5 / +40 °C
Continuous sound pressure level < 70 dB(A)