SEA saturn-boxer 2000 User manual

SATURN-BOXER
1000 - 2000
MOTOR REDUCER 120V~ FOR SLIDING GATES
International registered trademark n. 2.777.971
REV 02 - 12/201367411165
SEA USA Inc.
10850 N.W. 21st unit 160 DORAL MIAMI
Florida (FL) 33172
Phone:++1-305.594.1151 Fax: ++1-305.594.7325
Toll Free: 800.689.4716

SATURN-BOXER
267411165
International registered trademark n. 2.777.971
Details
General
An appliance shall be provided with an instruction manual. The instruction manual shall give instructions for the installation,
operation, and user maintenance of the appliance.
The installation instructions shall specify the need for a grounding-type receptacle for connection to the supply and shall stress the
importance of proper grounding.
The installation instructions shall inform the installer that permanent wiring is to be employed as required by local codes, and
instructions for conversion to permanent wiring shall be supplied.
Information shall be supplied with a gate operator for:
a) The required installation and adjustment of all devices and systems to effect the primary and secondary protection against
entrapment (where included with the operator).
b) The intended connections for all devices and systems to effect the primary and secondary protection against entrapment. The
information shall be supplied in the instruction manual, wiring diagrams, separate instructions, or the equivalent.
Vehicular gate operators (or systems)
A vehicular gate operator shall be provided with the information in the instruction manual that defines the different vehicular gate
operator Class categories and give examples of each usage. The manual shall also indicate the use for which the particular unit is
intended as defined in Glossary, Section 3. The installation instructions for vehicular gate operators shall include information on
the Types of gate for which the gate operator is intended.
A gate operator shall be provided with the specific instructions describing all user adjustments required for proper operation of the
gate. Detailed instructions shall be provided regarding user adjustment of any clutch or pressure relief adjustments provided. The
instructions shall also indicate the need for periodic checking and adjustment by a qualified technician of the control mechanism
for force, speed, and sensitivity.
Instructions for the installation, adjustment, and wiring of external controls and devices serving as required protection against
entrapment shall be provided with the operator when such controls are shipped with the operator.
Instructions regarding intended installation of the gate operator shall be supplied as part of the installation instructions or as a
separate document. The following instructions or the equivalent shall be supplied where applicable:
a) Install the gate operator only when:
1) The operator is appropriate for the construction of the gate and the usage Class of the gate,
2) All openings of a horizontal slide gate are guarded or screened from the bottom of the gate to a minimum of 4 feet (1.22
m) above the ground to prevent a 2-1/4 inch (57.2 mm) diameter sphere from passing through the openings anywhere in
the gate, and in that portion of the adjacent fence that the gate covers in the open position,
3)All exposed pinch points are eliminated or guarded, and
4) Guarding is supplied for exposed rollers.
b) The operator is intended for installation only on gates used for vehicles. Pedestrians must be supplied with a separate access
opening. The pedestrian access opening shall be designed to promote pedestrian usage. Locate the gate such that persons will
not come in contact with the vehicular gate during the entire path of travel of the vehicular gate.
c) The gate must be installed in a location so that enough clearance is supplied between the gate and adjacent structures when
opening and closing to reduce the risk of entrapment. Swinging gates shall not open into public access areas.
d) The gate must be properly installed and work freely in both directions prior to the installation of the gate operator. Do not over-
tighten the operator clutch or pressure relief valve to compensate for a damaged gate.
e) (not applicable)
f) Controls intended for user activation must be located at least six feet (6’) away from any moving part of the gate and where the
user is prevented from reaching over, under, around or through the gate to operate the controls. Outdoor or easily accessible
controls shall have a security feature to prevent unauthorized use.
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SATURN-BOXER
3
67411165
International registered trademark n. 2.777.971
g) The Stop and/or Reset button must be located in the line-of-sight of the gate. Activation of the reset control shall not cause the
operator to start.
h)Aminimum of two (2) WARNING SIGNS shall be installed, one on each side of the gate where easily visible.
i) For gate operators utilizing a non-contact sensor:
1) See instructions on the placement of non-contact sensors for each Type of application,
2) Care shall be exercised to reduce the risk of nuisance tripping, such as when a vehicle, trips the sensor while the gate is
still moving, and
3) One or more non-contact sensors shall be located where the risk of entrapment or obstruction exists, such as the
perimeter reachable by a moving gate or barrier.
j) For a gate operator utilizing a contact sensor:
1) One or more contact sensors shall be located where the risk of entrapment or obstruction exists, such as at the leading
edge, trailing edge, and postmounted both inside and outside of a vehicular horizontal slide gate.
2) One or more contact sensors shall be located at the bottom edge of a vehicular vertical lift gate.
3) One or more contact sensors shall be located at the pinch point of a vehicular vertical pivot gate.
4) Ahardwired contact sensor shall be located and its wiring arranged so that the communication between the sensor and
the gate operator is not subjected to mechanical damage.
5) A wireless contact sensor such as one that transmits radio frequency (RF) signals to the gate operator for entrapment
protection functions shall be located where the transmission of the signals are not obstructed or impeded by building
structures, natural landscaping or similar obstruction. A wireless contact sensor shall function under the intended end-
use conditions.
6) One or more contact sensors shall be located on the inside and outside leading edge of a swing gate.Additionally, if the
bottom edge of a swing gate is greater than 6 inches (152 mm) above the ground at any point in its arc of travel, one or
more contact sensors shall be located on the bottom edge.
7) One or more contact sensors shall be located at the bottom edge of a vertical barrier (arm).
Revised 56.8.4 effective February 21, 2008
Instruction regarding intended operation of the gate operator shall be provided as part of the user instructions or as a separate
document. The following instructions or the equivalent shall be provided:
IMPORTANT SAFETY INSTRUCTIONS
WARNING – To reduce the risk of injury or death:
1. READAND FOLLOW ALL INSTRUCTIONS.
2. Never let children operate or play with gate controls. Keep the remote control away from children.
3.Always keep people and objects away from the gate. NO ONE SHOULD CROSS THE PATH OF THE MOVING GATE.
4. Test the gate operator monthly. The gate MUST reverse on contact with a rigid object or stop when an object activates the non-
contact sensors. After adjusting the force or the limit of travel, retest the gate operator. Failure to adjust and retest the gate
operator properly can increase the risk of injury or death.
5. Use the emergency release only when the gate is not moving.
6. KEEP GATES PROPERLY MAINTAINED. Read the owner’s manual. Have a qualified service person make repairs to gate
hardware.
7. The entrance is for vehicles only. Pedestrians must use separate entrance.
8. SAVE THESE INSTRUCTIONS.
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BOXER 1000BOXER 1000
1Adjustable foundation plate
2Anchor bolts
3Pinion protection
4Adjusting screws cover
5Pinion
6Reducer release lever
7 Screw for mechanical
clutch adjustment
(where present)
8Electronic unit
9Oil filling up cap
10 Magnetic encoder
MAIN PARTS DENOMINATION
DIMENSIONS (inches)
12.59
13.58
.46
8
SATURN-BOXER
TECHNICAL DATA
Power supply
Motor
Power
Absorbed current
Motor capacitor
Working frequency
Working Temperature
Thermoprotection
Weight
Anticrushing clutch
Protection degree
Pinion Z16 (Z20) speed
Maximum torque
Gate maximum weight
Mechanical clutch
Limit switch
Saturn 1000
120V (±5%) 50/60 Hz
120V 24V
400W 500W 100W
3,2 A 5,0 A
50 uf 70 uf -
25% 40% 60%
-4°F +131°F
302°F -
28.66 lb 31.96 lb 31.52 lb
Electronic Electr./Mech. Electronic
IP55
31.16 (36.08) feet/min Adjustable
55 Nm 70 Nm 60 Nm
2204.62 lb 4409.24 lb 3086.47 lb
no yes -
Inductive or mechanical
Saturn 2000
467411165
International registered trademark n. 2.777.971
MECHANICAL INSTALLATION
BOXER 2000BOXER 2000
4409.24 lb
2204.62 lb
SATURN 2000
SATURN 1000
40%
25%
Use frequency
Gate maximum weight
Motor reducers
SAT.1000
SATURN 2000
55%
The SATURN and the BOXER are motor reducers designed for
the automation of sliding gates with grease lubrication or in oil
bath, depending on the versions.
The irreversibility of the motor reducers allows a perfect and
safe gate closing, and makes the installation of an elecric lock
unneccessary. In case of electric power cut, the lock device
placed on the front part of the motor reducer allows the manual
opening and closing. The operators are equipped with an
electronic clutch device and adjustable mechanical clutch (if
present), which provides an adjustment of the thrust on the
gate, furthermore the electronic inversion system (optional)
through encoder makes out of the Saturn and Boxer motor
reducers a safe and reliable operators allowing in a simple way
to respect the laws in force in the country where the product will
be installed.
10
7
5
3
1
2
4
6
8
9
TECHNICAL DATA
Power supply
Power
Absorbed current
Motor capacitor
Working frequency
Working Temperature
Thermoprotection
Weight
Anticrushing clutch
Protection degree
Pinion Z16 (Z20) speed
Maximum torque
Gate maximum weight
Mechanical clutch
Limit switch
120 V (±5%) 50/60 Hz
400W 500W
3,2 A 5,0 A
50 uf 70 uf
55%
-4°F +131°F
302°F
30.86 lb 33.06 lb
Electronic Electronic/Mechanical
IP55
31.16 (36.08) feet/min
55 Nm 70 Nm
2204.62 lb 4409.24 lb
no yes
Inductive or mechanical
Boxer 1000 Boxer 2000
Saturn 1400 24V OIL
60%
SATURN 1500 24V OILSATURN 1500 24V OIL
3306.93 lb
SATURN - BOXER MOTOR REDUCERS USING GRAPHIC
REV 02 - 12/2013

Fig. 1
Fig. 2
Fig. 3 Fig. 4
Fig. 5
Fig. 6
1/2”
1/4”
5”
Fig. 7
Install the warning signs, on both sides of the gate which informs the
pedestrians about the danger they run when passing or resting in the
environment of the gate (fig. 10).
Important:
For a higher security, SEA advices to install infrared
photocells.
2. PRECAUTIONS
Saturn and Boxer have been created for the automation of gates used
by vehicles only. Pay very much attention to avoid the crossing of the
gate path it is very dangerous for pedestrians (fig. 8).
Make sure that no person not belonging to the company somehow
activates the automation or acts on it from the outside (fig. 9).
GATE WARNINGS AND PRECAUTIONS
!!
WARNING
Moving Gate Can Cause
Serious Injury Or Death
- KEEP CLEAR ! Gate may move at any time
without prior Warning.
- Do not let children operate the gate or play in
the gate area.
- This entrance is for vehicle only.
Pedestrians must use separate entrance
3. TYPE OF INSTALLATION
A front installation is the right and only possible installation, it is highly
recommended to install two security gate stops on the two extremities of
the rail to prevent the gate from derailment (fig. 11).
Fig. 10
!!
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Fig. 11
Over-Travel Stop
Over-Travel
Stop
SATURN-BOXER
67411165 5
International registered trademark n. 2.777.971
1. GATE ARRANGEMENT
The first thing to check is that the gate is in good running order as
follows:
a) The gate is rigid and straight and runs smoothly throughout its
travel.
b) that the inferior sliding guide-rail is perfectly straight and horizontal
to avoid a derailment of the gate (fig. 1); furthermore it must be free of
irregularities and foreign bodies which could obstruct the normal run
of the gate (fig. 2 and 3).
c) that the upper guides are not fixed (fig. 4) but furnished with rollers
d) that the distance between the end of the gate (in maximum opening
position) and the eventual wall must be at least of 5 inches (fig. 7)
which allow the sliding of the gate without difficulties (fig. 5 and 6).
e) The lower support wheels have sealed
bearings or grease points.
f) The top guide must be manufactured and
installed so that the gate is perfectly upright.
g) Physical gate stops must be fitted to
prevent the gate coming out of its guides and
track.
Fig. 8
Fig. 9
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Fig. 13
Z16
Z20
4.25 in
4.56 in
MINIMUN DIMENSION Q
4.2. Before concreting in the plate insert a flexible plastic duct
into the special hole of the plate.
4.3. Before concreting in the plate, make sure that it is perfectly
leveled and that the distance of 2,28-2,63 in. as shown in Fig. 13
is respected.
Ø
1.18 in. Minimum
4. FOUNDATION PLATE ANCHORAGE
To install the foundation plate it is necessary to:
4.1. Prepare a concret basement with the dimensions shown in
Fig. 12 where the foundation plate and the anchor bolts will be
concreted.
NOTE: It is recommended, gate structure permitting, to lift the
foundation plate about 1.96 in. from the ground, in order to avoid
eventual water stagnation.
1.69-2.28
Fig. 16
6. FITTING OF THE MOTOR REDUCER
6.1. Insert the 4 grains into the special holes, so that it is
possible to adjust the motor reducer height on the plate (Fig. 15).
At the end of installation check if the 4 crub screws are well
gripped on the foundation plate.
6.2. Fix the motor reducer to the foundation plate with the 2
included nuts, adjusting the side position (Fig. 16) so to respect
the shown quota in (Fig. 13).
6.3. Remove the closing loading oil cap (red) and substitute
it with that supplied apart provided with the airhole (black).
5.90
16.53
9.84
Plinto
Fig. 12
2.28-2.63
2.55
Max 0.19 in.
5. CABLES PASSAGE ARRANGEMENT
Saturn and Boxer are provided with two different holes for
electric cables passage.
It’s very important to make the high - tension (120V~) cables
pass through one hole and the low - tension cables (24V )
through the other one (Fig. 14)
SATURN-BOXER
MECHANICAL INSTALLATION
67411165
6
International registered trademark n. 2.777.971
Fig. 14
Hole 1
Hole 2
Fig. 15
REV 02 - 12/2013

Fig. 21
0.059 in.
7.4. Make sure that all the gear rack elements are perfectly
aligned and placed correctly (teeth in phase). It’s suggested to
place two aligned elements infront of a third one as shown in
Fig.20;
7.5. Repeat the above described operation for all the remaining
gear rack elements which have to be installed;
7.6. To avoid that the door weights down on the pinion (Fig.21)
lift up the whole rack about 0.059 in.
Warning: Keep a gap of about 0,019 in. between pinion tooth
and gear rack tooth;
7.7. Make sure that the gear rack works at the center of the
pinion along all rack elements, if necessary, adjust the distance
pieces length.
Fig. 18
ABC
Fig. 17 Fig. 20
Fig. 19
SATURN-BOXER
67411165
MECHANICAL INSTALLATION
International registered trademark n. 2.777.971
8. LIMIT SWITCH ADJUSTMENT
8.1. In order to install and adjust the limit switch in opening, follow
the below mentioned instructions (Fig. 22):
- Take the gate to complete opening,
- Place the small plate on the gear rack so that the limit switch is
(small lever in case of mechanical limit switch (Fig. 23); small
pointers placed on the upper part in case of inductive limit switch
(Fig. 24)) in corrispondence of pointX which is placed 1.96 in.
from the folded side of the small plate (fig. 25) and fix it with the
delivered screws (Fig. 26 - Fig.27).
8.2. In order to install and adjust the limit switch in closing, follow
the below mentioned instructions (Fig. 22):
- Take the gate to complete closing
- Place the small plate on the gear rack so that the limit switch is
in corrispondence of pointX which is placed 1.96 in. from the
folded side of the small plate (fig. 25) and fix it with the delivered
screws (Fig. 26 - Fig.27).
Fig. 22
Limit switch in closing
Limit switch in opening
7
7. GEAR RACK MOUNTING
7.1. Release the motor and open the leaf completely;
7.2. Fix on each gear rack element the support pawls with the
appropriate lock screws, make sure to put them in the upper part
of the hole (Fig. 17) ;
7.3. Lean the gear rack element on the toothed pinion of the
motor in parallel to the ground slideway of the gate, as shown in
Fig. 18 and electrically weld the central pawl B to the gate
structure (Fig. 19).
Manually move the gate until pawl C is placed corresponding to
the pinion and fix it through electric welding. Repeat the same
procedure for pawl A after having placed it corresponding to the
pinion;
REV 02 - 12/2013

Fig. 24
Adjusting the trimmer for braking, placed on the electronic
control unit, it is possible to make the gate stop on the desired
position.
9. GROUNDING (Fig. 28 - Fig.29)
Inductive limit switch
Fig. 26
1.96 in.
X
Fig. 25
Position in which must be the spring
(mechanical limit switch) or the
pointer (inductive limit switch)
SATURN-BOXER
67411165
8
MECHANICAL INSTALLATION
International registered trademark n. 2.777.971
Mechanical limit switch
Fig. 23 Fig. 27
Fig. 28
Fig. 29
F
N
Example: Boxer
Example: Saturn 24V
REV 02 - 12/2013

SATURN-BOXER
MECHANICAL INSTALLATION
International registered trademark n. 2.777.971
10. CLUTCH ADJUSTMENT (Where present)
10.1. Switch off electric power.
10.2. In order to adjust the clutch it is necessary to:
-Act on the scrub screw “A” (Fig. 30) as follows:
- Turning clockwise = less clutch sensibility / more thrust force
-Counter clockwise = more clutch sensibility / less thrust force
11. SCREW COVER MOUNTING
At the end of the mechanical installation and after having
executed all the required adjustments, mount the two screw
covers on the operator as shown in Fig. 31.
Fig. 31
Fig. 30
AA
Ex. Boxer
+ power
- sensibility
- power
+ sensibility
12. ELECTRIC CONNECTIONS OF THE
INSTALLATION (Fig. 32)
1) Saturn - Boxer
2) Photocell Sx
3) Photocell Dx
4) Mechanical safety edge
5) Key push botton
6) Flasher
7) Receiver
8) Warning notice
9) Junction box
10) Differential Fig. 32
1
2
3
4
10
5
6
7
8
9
2
The cable mesures are indicated in mm
13. RISK EXAMINATION
The points pointed by arrows in Fig. 33 are potentially dangerous. The
installer must take a thorough risk examination to prevent crushing,
conveying, cutting, grappling, trapping so as to guarantee a safe
installation for people, things and animals (
)
Re. Laws in force in the
country where the installation has been made.
14. NOTICE
SEA USAInc. can not be deemed responsible for any damage or
accident caused by product breaking, being damages or
accidents due to a failure to comply with the instructions herein.
The guarantee will be void and the manufacturer responsibility
will be nullified if SEA USA Inc. original spare parts are not being
used.
Packaging materials such as
plastic bags, foam polystyrene, nails etc must be kept out of
children’s reach as dangers may arise.
The electrical installation shall be carried out by a
professional technician who will release documentation as
requested by the laws in force.
Fig. 33
15. PERIODIC MAINTENANCE
All the above described operations must be done exclusively by
an authorized installer.
Check the oil level (where present)
(Use the oil level rod)
Change oil
Check the release functionality
Check the clutch functionality
(where present)
Check the distance between pinion and gear
rack (0,059 in.)
Check the usury status of pinion and
gear rack
Check the fixing screws
Check the connection cables integrity
Check limit switch functionality and status in
opening and closing and the related
small plates
Annual
4 years
Annual
Annual
Annual
Annual
Annual
Annual
Annual
67411165 9 REV 02 - 12/2013

SATURN-BOXER
MECHANICAL INSTALLATION
International registered trademark n. 2.777.971
16. RELEASE SYSTEM
16.1. To release procede as follows:
- Insert the key, push and turn about 90° clockwise (Fig. 34).
- Pull the release lever until it stops, about 90° (Fig. 35).
Note: when pulling the release lever the electronic control unit receives a stop impulse through the micro-
switch placed on the inside (if present).
16.2. To relock procede as follows:
- Push the release lever to complete closing.
- Rotate the key counter-clockwise and extract it.
Once the lock has been restored the electronic control unit is reactivated (only if a micro-switch is mounted) .
FOR SATURN
17. RELEASE SYSTEM FOR BOXER
17.1. In order to release do as follows:
-Open the lock cover, insert the key and rotate it 90° clockwise (Fig. 36).
- Pull the release lever until it stops, about 90° approximately (Fig. 37).
Note: when you pull the release lever, the electronic control unit receives a stop impulse thanks to a micro-
switch placed inside.
17.2. In order to relock do as follows:
- Push the release lever to complete closing.
- Rotate the key counter-clockwise and extract it.
- Close the protective lock cover.
Once the lock has been restored the electronic control unit reactivates
Fig. 26
Fig. 24
Page for both instaler and user
Fig. 23
sC l o eOpen
Push and
turn
Open
Close
Fig. 25
67411165
10 REV 02 - 12/2013

GENERAL WARNING: Installation must be realized using parts and accessories approved by SEA. SEA is not
responsible for incorrect installations and/or non-compliance with safety standards according to the law in-force. SEA
is in no way liable for any damages and/or malfunctioning due to using parts and accessories non-compliant with the
UL325 safety standards.
ORDERS: Orders are processed upon approval by SEA. Buyers must confirm orders by sending a written Purchase
Orders to SEA. Purchase Orders are intended as confirmation of orders and binding for the buyer, which accepts SEA
sales condition.
QUOTATION: Quotation and special offers with a non-specified duration expires automatically after 30 days.
PRICES: Prices are based on the Price List in force. Discounts and quotation from Sales Rep. and other selling
branches must be approved by SEA. Prices are F.O.B SEA Warehouse in Miami and do not include shipments costs.
SEAreserves the right to modify the price list at any time and provide notice to its sales network.
PAYMENT: Method of payments and terms are notified by SEAand displayed on the commercial invoice.
DELIVERY: The delivery time on the invoice is not binding and represents an estimated delivery. Shipments costs will
be charged to the buyer and SEA is not responsible for delays and/or damages occurred to the products during
shipment.
COMPLAINS: Complains and/or claims must be notified to SEA within 7 business days after receiving the products.
Claims and complains must be supported by original documents. Customer must contact the factory for instructions
and authorization. Merchandise returned for credit must be current, uninstalled and unused and returned in its original
packaging. Freight must be pre-paid on all authorized returns.
REPAIRS: Repairs and parts are subject to the availability in stock. Shipment of products for repairs must be pre-paid
by the customer. Products shipped without authorization, sender’s details and description of the problems will be
refused. Customers must contact SEAfor instructions.
WARRANTY: for the original buyer only:
Hydraulic and oil-bath motors: 36 months warranty from the date of invoice on manufacturing, assembling and
workmanship defects.
Electro-mechanic motors and electronic control systems: 24 months warranty from the date of invoice on
manufacturing, assembling and workmanship defects.
Lepus and Full Tank Standard model: 60 months warranty from the date of invoice on manufacturing, assembling and
workmanship defects.
No warranty will be recognized for damages due to incorrect installation and/or improper use for which the product was
intended. SEA warranty obligations shall be limited to repair or replace the defective product/parts at SEA option, upon
examination of the products by SEA technical Staff. All replaced parts must remain property of SEA. The warranty
status of the product remains an unquestionable assessment of SEA. Buyer must ship pre-paid defective products.
Products under warranty will be returned pre-paid by SEA. Recognized defects, whatever their nature, will not produce
any responsibility and/or damage claims to SEA USA Inc and SEA s.r.l. Warranty shall not cover any required labor
activities. Warranty will in no case be recognized if alterations and any other changes will be found on products.
Warranty will not cover damages caused by carriers, expendable materials and faults due to improper use with the
products specifications. No indemnities are recognized during repairing and/or replacing of the products under
warranty. SEA USA Inc. and SEA s.r.l. decline any responsibility for damages to person and objects deriving from non-
compliance with safety standards, installation instructions or use of the products sold. It is intended that warranty will be
recognized only on products bought through the SEAauthorized network. Products must be installed by professionals.
No warranty will be recognized if products are installed directly by the final user. Warranty does not apply in case of
unexpected events such as fire, flood, electrical power surge, lightning, vandalism and others.
SEA USA Inc. is not responsible for errors in technical information printed in catalogs and installation
manuals.
SALES CONDITIONS
SATURN-BOXER
67411165
International registered trademark n. 2.777.971
11
REV 02 - 12/2013

web site: www.sea-usa.com
e-mail: [email protected]
International registered trademark n. 2.777.971
SEA USA Inc.
10850 N.W. 21st unit 160 DORAL MIAMI
Florida (FL) 33172
Phone:++1-305.594.1151 Fax: ++1-305.594.7325
Toll Free: 800.689.4716