tousek REX Force Technical document

Mounting and operating manual
Swing gate operator REX Force

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This manual is the sole property of the TOUSEK Ges.m.b.H. and may not be made available to competitors. All rights reserved. No part of it may be reproduced without our prior
written permission. We will not accept liability for any claims resulting from misprints or errors. This edition of the manual replaces all earlier publications of the same.
Index
General warning and safety notes.................................................................................................................... 3
1. Notes, general characteristics, function, technical data, Warning notes ......................................................... 4
2. Montage ........................................................................................................................................................ 5
3. Control ...................................................................................................................................................... 13
Warnings - connection works ......................................................................................................................... 13
Programming, Menu structure............................................................................................................ 19–21
Connections and adjustments ................................................................................................................. 22
Buttons / switches............................................................................................................................... 22
Photocells ........................................................................................................................................... 24
Safety edges....................................................................................................................................... 26
Left leaf ............................................................................................................................................... 28
Right leaf............................................................................................................................................. 28
Operating mode .................................................................................................................................. 29
Light / lamps ....................................................................................................................................... 30
Peripherals.......................................................................................................................................... 31
Diagnosis ............................................................................................................................................ 35
4. Connecting the receiver ................................................................................................................................. 36
5. Putting into operation ..................................................................................................................................... 37
6. OptionalTra󰀩clightcontrolunitSTA11........................................................................................................ 41
7. troubleshooting guide..................................................................................................................................... 47
8. Cable plan ...................................................................................................................................................... 48
9 Dimensioned drawing operator REX.............................................................................................................. 49
10. Dimensioned drawing housing ST REX ........................................................................................................ 50
11. Maintenance plan .......................................................................................................................................... 50

tousek / EN_REX-Force_01 / 25. 03. 2020 - 3 -
Important warning and safety notes for installation and operation
• These installation- and operating instructions form an integral part of the product “gate operator”. They have been specically written for professional installers
trained and skilled in the trade and should be carefully read in their full length before carrying out the installation. They describe the proper installation and
operation of the sliding gate operator only, not of the overall device “automatic gate”. After the installation this manual has to be handed over to the user.
• Installation, connection, adjustments, putting into operation, and servicing may only be carried out by trained profes-
sionals in full accordance with these installation- and operating instructions.
• The EU Machine Directive, laws and rules concerning the prevention of accidents, and laws and standards which are in force in the EU and in the individual
countries have to be strictly followed.
• The TOUSEK Ges.m.b.H. cannot be held liable for any claims resulting from disregards of the laws and standards in force during the installation and operation.
• The product may only be used in accordance with its original purpose, for which it has been exclusively designed, and which is described in these instal-
lation and operating instructions. The TOUSEK Ges.m.b.H. rejects any liability if the product is used in any way not fully conforming to its original purpose
as stated herein.
• The product is not suitable for installation in explosion-hazardous areas. The existance of inammable gas and steam
is of great danger !
• The packaging materials (cardboard, plastic, EPS foam parts and lling material etc.) have to be properly disposed of in accordance with the applying
recycling- and environmental procection laws. They may be hazardous to children and therefore have to be stored out of children´s reach.
• Before beginning with the installation the installer has to make sure that all mechanical components of the gate facility, like carrier prole/rail, gate frame and
panels, guiding elements etc. are sufciently supportive and resistant for the purpose of gate automation. Check also whether the product has transport
damages.
• All electrical installations have to be made in full conformity with the applying rules and laws (e.g. using a fault current circuit breaker, proper grounding etc.).
• An all-pole disconnecting main switch with a contact opening-gap of minimum 3 mm has to be foreseen.
• When installing the safety device (photocells, safety edges, emergency-stops etc.) please comply with the valid direcitves/standards, the criteria of practical
rules of conduct, the installation environment, the operating logic of the system and the effected force of the motorised gate. .
• The safety devices must secure possible bruise, shear and general danger areas of the motorised gate.
• After installation the proper function of the gate facility and the safety devices has to be checked!
• Place warning signs and notes of the valid regulations to indicate danger areas .
• With each installation the identication data of the motorised gate has to be placed in a visible place.
• The label for the Handauslöser has to be placed next to its operating element.
• The electric motor heats up during operation. Therefore the device should only be touched after it has cooled off.
• Please make sure that no other persons are on site of the motorised gate area, especially in when operating the facility in hold to run mode (switch with
OFF-pre adjustment) . The pre-adjusted OFF-button/switch has to be placed in sight of the actuated gate but away from moving parts. This switch/button
(except key-switch) has to be mounted in min. 1,5m height and non-accessible to the public.
• Children have to be instructed, that the gate facility as well as the belonging parts may not be used improperly, e.g. for
playing. Furthermore handheld transmitters have to be kept in safe places and other impulse emitters as buttons and
switches have to be installed out of children‘s reach.
• Only original spare- and replacement parts may be used for repair of the product.
• The TOUSEK Ges.m.b.H. rejects any liability for claims resulting from usage of the product in combination with components or devices which do not fully
conform to the applying safety laws and rules.
• The installer has to inform the user about all aspects of the automatic operation of the complete gate facility, as well as about emergency operation. The
installer further has to supply to the user all instructions relating to the safe operation of the gate facility. The installation and operating instructions also
have to be handed over to the user.
• The user has to be informed that he has to turn off the main power switch in case of malfunction of the product and that he can use the facility again after
repair and adjustment works have been completed.
• Please notice that the warranty will not be applicable if the label with the engine number has been removed or
damaged.
Maintenance
• Disconnect the power supply during mounting, maintenance and repair works.
• Maintenance works may only be carried out by qualied personnel.
• Check the proper force adjustment once a month.
• Check the proper function of the emergency release mechanism periodically.
• Check if all mounting screws are securely fastened periodically.
• Remove dirt from the operator periodically.
• Maintenance and servicing of the complete gate facility has to be carried out according to the gate builder’s/
installer’s instructions.

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1. General REX Force
Product features REX Force
Suitable for heavy duty use (100% duty/cycle)
Large, illuminated LC-Display (2x16 characters)
Clear text menu programmable via four buttons
Operation mode is selectable (Impulse, Automatic, Deadman)
Free adjustable partial opening (also for 1 leaf)
Traffic light function in combination with the traffic light
controlSTA 11 (one way traffic or two way traffic regulation)
Distance measurement via absolute encoders (no limit
switches), no need of learning the way after unlocking or
blackout.
Adjustable soft stop (distance and speed
Adjustable speed (separately for OPEN and CLOSE),
controlled by a frequency converter
Motor locking function with optional motor locking module
Mechanical brake for safe gate stop
Electronic monitoring of emergency release
Directconnectionofseparate8,2kΩsafetycontactedges
(inside/outside)
Input for gate back area surveillance
Separate input for I-loop detectors
Status display for safety inputs and push button inputs
Self-monitoring of photocell
Connection slot for radio receiver
12Vd.c. flashing light output
Integrated event message contact
Optional, external gate status display (e.g. for concierge)
Optional courtyard lamp module (230V, 100W)
Function REX Force
The control unit can be adjusted in 3 logic modes:
• Impulse mode: with open and close switch function
• Automatic mode: automatic closing
• Dead-man mode: gates moves as long as switch/button is pressed
Depending on the door situation (1 or 2 leaves), the main control unit ST REX gets connected via BUS cables to one or two ST
REX smart motor control units. The ST REX smart manages the brake, the emergency release, the motor and the frequency
converterandhastwoinputsforthedirectconnectionof8.2kΩcontactstrips(separatedforinside/outside).Furthermore,
the ST REX has a traffic light function when used in combination with the traffic light control STA 11. The connection to the STA
11 is also established via a BUS line ( page 16, 41).
Technical data
REX Force
supply voltage 230V a.c. ±10%, 50Hz weight REX Force 99kg
motor voltage 3 x 230V a.c. max. wing width 12m
max. current consumption 2A (excl. accessories) max. wing weight 1500kg
travel speed 1,3°/s –3°/s
internal limit stops up to
max. 6m wing width, max. 700kg per wing
(external limit stops for higher values necessary!)
nominal torque 2000Nm
max. torque 3500 Nm ambient temperature -20°C to +40°C
duty cycle in S1 mode 100% emergengy release
output photocells 24Va.c. Motor bolt output 24V d.c. (optional with module)
ashinglightoutput 230Va.c. und 12Vd.c.
(über Blinkprint) magnetic clamp output 24Vd.c. (optional with module)
force adjustment frequency converter Article no. 11260500
Optional equipment
pluggable receiver • flashing light module • additional module for courtyard/control lamp • additional
module for gate status • motor bolt module • traffic light control unit
Note: the max. leaf widths here indicated are for wind permeable and non-raising gates!
• To esnsure a perfect operation an all-current-sensitive residual current circuit breaker
type B must be used!
• DANGER: Please note that due to the big mass of the gate and its high speed, a huge kine-
tic energy gets generated. This must be necessarily taken into account when planning and
constructing the gate. The external limit stops and the mechanical construction have to be
dimensioned accordingly!

tousek / EN_REX-Force_01 / 25. 03. 2020 - 5 -
Important: Mounting position of the operator
• The mounting position of the REX operator must be selected according to the given door situation and the
planned opening angle of the door:
! Whenplanningorinstallingtheoperatormakesurethatthereisasu󰀩cientspaceforthegateandthemotor
arm (2) even in the open position of the gate.
!It is essential to note the dependence of the mounting position of the operator on the planned opening angle of
thedoorsothatacollisionbetweenthedoorandtheoperatorwhenopeningisexcluded.Futhermoresu󰀩cient
space for the installation of safety edges must be available to secure safety-relevant points. The safety edge
must not be triggered by an operator arm or the gate itself.

see also installation examples page 9–11
2. Mounting REX Force
General installation instructions
• The operator REX force is equipped with internal limit stops which are used to set the end positions OPEN and CLOSE.
These can be used for gates up to a max. wing width of 6m and a max. gate weight of 700kg.
For gates that exceed these values, external limit stops with su󰀩cient dimensions must be provided !
• *) Attention: In order to avoid soiling and to ensure a permanently reliable operation, a minimum distance of 500mm
to the upper edge of the roadway should be maintained.
!
!
(1) Motor console
(2) Motor arm
(3) Elbow
(4) Gate arm
(5) Gate console
(S1) Safety edges
Danger !
• Please note that moving machine parts and gate systems
form danger spots.
• Therefore set up protective measures to safeguard the
danger points: Anti-trap protection using safety edges
(S1).
• Please observe the valid standards and guidelines
when setting up automatic gate systems!
*) min. 500mm
!!
5!!
4
S1
S1
23
1

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Overview REX Force
(1) Motor console
(2) Motor arm
(3) Elbow
(4) Gate arm
(5) Gate console
(6) Drive chain
(7) Chain tensioner (Check chain tensi-
on with each service!)
(8) Adjustable limit stops
(9) Absolute encoder
(10) Emergency release with transmission
cable (10a)
(11) Additional cover below
(12) Integrated control board
12
MK
2
4
8 8
6
1a
1a
View from below View from above
2
1a
1a
9
1
Supply of connection cables (1a):
The motor console (1) is used to
attach the operator to the column.
Furthermore the connecting cables
are led into the operator via the
openings of the motor console to
the integrated control board (12).
7
10a
4
5
10
11
10a
2
3

tousek / EN_REX-Force_01 / 25. 03. 2020 - 7 -
Gate arm REX Force (4) with screwable gate console (5)
• Measurements in mm
(4) Gate arm
(4a) 2x ball-link M16
(5) Gate console
(5a) Hexagon head bolt M16
(5b) Nut M16
Gate console (5)
• Maße in mm
1182
1000
650
832
Ø16
SW 24 SW 24
5
220
150
18
302
25
SCHNITT A-A
50
340
302
220
150
A▼ A▼
97,597,5
Cut A-A
50
25
340
Ø18
4848 2828
136
86
11
160
66,6
46,6
R20
46,6
66,6
160
R20
Ø14
Ø11
86
136
28 48
Motorkonsole (1)
• Measurements in mm
The connecting cables are led
from the rear into the operator
via the openings (1a) of the
motor console.
1a
For special door situations please indicate the door dimensions
(plan) to determine the mounting position and the length of the
door arm.
5
1
5
5a 4 4a4a
5b

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Important
Note the following assembly criteria:
• Motor arm (2) and elbow (3) are assembled differently depending on the opening direction
(left/right, viewed from the inside).
• For a left-hand operator the elbow (3) musst be turned over.
• The motor arm must be placed on the operator at the correct angle in accordance with the
door situation and fixed with the Hexagon head bolts (2a) so that the planned installation
point of the gate console (5) can be implemented with the door closed in conjunction with
the door arm (4).
• Make sure there is enough room for movement so that neither the gate nor the motor arm
is restriced or collided during opening. Also plan the necessary space for safety edges.
These are used to protect dangerous areas and must be planned in such a way that they
can not be triggered by the gate or the motor arm.
• Set jumpers J1/2 (1-wing/2-wings) and JF (left-/right-operator) according to your door
situation 
page 14, 15
Condition as delivered:
right operator
2
3
2a
View from below
DANGER: The possible high gate weight or high speed can cause a very high
kinetic energy. The mechanical door construction and external limit stops for
the gate must be dimensioned accordingly!
2
3
Left INSIDE Right
2
3
8
8
adjustable
4 45 5

tousek / EN_REX-Force_01 / 25. 03. 2020 - 9 -
!Neither the gate nor the motor arm may be restriced in the movement. Also provide the necessary sppace for
safety edges. These are used to safeguard danger spots and must be planned in such way that they can not be
triggered by the gate or the motor arm.
1150
400
50
165
820
360
View A
(X1) Turning point Motor arm
(X2) Turning point gate
View B
Mounting example 1: entrance width = 6m, opening angle 95°
• Measurements in mm
X1
!
650
68
120
50
350
400
1068
X1
X2
X2
!
View B
Gate opened to the inside 95°
View A
Gate closed
6000
95°
!

- 10 - tousek / EN_REX-Force_01 / 25. 03. 2020
!Neither the gate nor the motor arm may be restriced in the movement. Also provide the necessary sppace for
safety edges. These are used to safeguard danger spots and must be planned in such way that they can not be
triggered by the gate or the motor arm.
Mounting example 2: entrance width = 6m, opening angle 110°
• Maße in mm
View A
(X1) Turning point Motor arm
(X2) Turning point gate
View B
165
50
400
1000
820
360
X1
X2
!
1271
400
570
50
340
650
56
X1
X2
!
!
6000
110°
View B
Gate opened to the inside110°
View A
Gate closed