Wisniowski MakroPro 100 User manual

Operating and Installation
Instructions
Sectional gate MakroPro 100
MakroPro Alu 100
installation type STL HLP
Catalog no. AW.03.40
Operating and Maintenance Manual
Last Update - 10th May, 2006

IMPORTANT INFORMATION
EXPLANATIONS OF SYMBOLS
1. DESIGN CHARACTERISTICS & TECHNICAL SPECIFICATION
2. APPLICATION AND FUNCTION
3. SAFETY RECOMMENDATIONS
4. REQUIRED INSTALLATION CONDITIONS
5. INSTALLATION
Please read these instructions carefully and follow the guidelines. You will
find here essential information, which guarantees safe installation and use
as well as proper maintenance of the sectional gate MAKROPRO 100.
Please protect these instructions from damage and store them carefully.
Numbers shown in fig. 1 correspond directly to numbers of drawings
included in these instructions.
A1 - gate leaf
A2 - vertical guide assembly L
A3 - vertical guide assembly P
A4 - guide coupler
A5 - console
A6 - line drum
A7 - drive shaft
A8 - carrier
A9 - side gasket
A10 - upper hinge
A11 - side hinge
A12 - protection from cable breaking
A13 - lock/bolt
A14 - bottom gasket
A15 - middle hinge
H - opening height
S - opening width
S - custom order width
N - lintel
E - garage depth
W1 - side space L
W2 - side space P
L - cable length (specified in the guarantee certificate)
- refers to installation of the gate with bolt
- refers to installation of the gate with lock
We offer as a standard MAKROPRO 100 series sectional gates designed
for mounting in door-way dimensions as indicated by the hatched area
on fig 2. Gates outside of the dimensional range specified below can be
made after prior arrangement made with WIŚNIOWSKI.
As a standard MakroPro 100 gates are made as industrial type gates.
Gates higher than 2100 [mm] and up to 5000 [mm] in width can
be equipped with pass door opening to the outside. Gates with a width up
to 5500 [mm] can be provided with glazed sections, maximum number
of windows is given in the price list.
Sectional gates MAKROPRO 100 are made from steel panels filled with
polyurethane foam. As a standard the gates are provided with devices
protecting the gate leaf from falling down in case of breaking of the cables,
holding the gate leaf. In case of failure this device blocks the leaf in safe
position.
Sectional gates MakroPro 100 are external building partition used
for closing garage and technical rooms, industrial facilities, in halls and
storage houses. When in closed position they make a tight vertical
partition of rooms, and when being opened allow taking in or out vehicles
or industrial equipment. Due to corrosion protection applied the
gates may be used for their intended purpose, in environments with
corrosion category C1, C2 and C3 according to PN-EN ISO 12944-2 and
PN-EN ISO 14713.
Before attempting to install and operate the door you must carefully read
and understand the guidelines provided in these instructions. Following
the gate installation and operation guidelines will ensure its correct
installation and provide long and trouble-free service. All operations
connected with installation of the gate should be carried out following the
steps described.
The gate should be used and operated according to its design purpose.
Selection and use of gates in building applications should be based on the
technical documentation of the building, drawn according to the Building
Law, binding standards ad other provisions - in particular according with
the decree of the Minister of Infrastructure dated 12th of April 2002
regarding technical criteria for buildings and building locations (Journal
of Law, No. 75, pos. 690 with later amendments). Sectional gates
MakroPro 100 can be mounted into reinforced concrete walls, walls made
of bricks or steel frameworks. The room intended for gate installation
should be fully finished (plastered walls, finished flooring), the walls must
not show flaws in completion of the job (fig. 4). The room should be free
from any chemical substances harmful to varnish coating. The floor around
the bottom washer should be leveled and made in such a way
to ensure free water removal. For proper installation of the gate
you need lintel N to mount the guides and drive, and side space
W1 and W2, with the minimal width required to install the gate shown
on fig 5.1 and 5.2. Correct measurement of lintel height and width of side
space is shown on fig 5.
Correct functioning of the gate depends to a great extent on its proper
installation. The manufacturer may, if optionally ordered by the
Client, install the gate or recommends authorized installation performers.
Should the user choose to install the gate by himself, he must ensure that
the guidelines contained in this manual are observed, to avoid incorrect
functioning of the gate, its premature wear and voiding guarantee claims.
Installation must be performed in accordance with binding standards
and provisions and relevant design documentation.
1. Screw down consoles to vertical guides (fig. 8).
2. Push the guides against the wall and face them with the opening
and set precise spacing of the consoles by means of clamping channel
fixing it temporarily to consoles (fig. 9).
3. Check spacing of consoles as shown on fig. 7.
4. Move the guides and consoles aside, mark off mounting holes
in the wall (fig. 10) and fit the plugs of wall fixing into drilled holes
(fig. 10-13).
5. Fix the vertical guides to the wall (fig. 12-13), optionally bracing L
section can be used (fig. 14).
6. Unscrew clamping channel from the consoles (fig. 15).
7. Remove the consoles from the vertical guides (fig. 15.3) and fix them
(movably) by means of assembly tacks to horizontal guides (fig. 16).
8. Put the horizontal guide with the console to the opening, face it with
the vertical guide and tighten with screws (fig. 16.5-16.7).
9. Push the consoles against the wall and screw down permanently to the
horizontal guides and to the wall (fig. 16.9-16.11).
10. Check the diagonals of the mounted guides (fig. 17).
11. Fix the horizontal guides to the ceiling using assembly hangers
(fig. 18).
12. Install the bumper to the horizontal guides (fig. 23).
13. Fit the clamping cross-bar to the horizontal guides (fig. 24).
14. Mount the drive shaft and lubricate the bearings with grease
(servomotor SI 55 - fig. 27-29, servomotor SI 17, SI 25, SI 40 - fig. 34).
15. Mount the gate drive - slide the key on the shaft, slide over the
servomotor (SI 55 - fig. 30, SI 17, SI 25, SI 40 - fig. 35) and secure
it with a ring (SI 55 - fig. 33, SI 17, SI 25, SI 40 - fig. 37).
16. Mount the cable (fig. 41).
17. Wind the cable on the drum (after winding three turns cut-off the
remaining cable, and protect its end from unwinding) (fig. 38)
- tighten firmly the plates securing the cable.
18. Mount the gate leaf (fig. 39-48).
19. In order to ensure proper gap between the panels during installation
of the panels use cardboard templates with a thickness of approx.
2 [mm], which should be placed between the panels near each hinge.
(fig. 42). The cardboards should be removed during opening
of the gate, when the panels are bent to each other (fig. 51.1).
20. Install the bolt/lock (fig. 49).
o
o
z
(drawing number) a
(drawing number) b
Design and specification are subject to change
(resulting from technological progress) without notice.
5.1. Installation sequence
To avoid damage and facilitate inspection (if brake
is activated) do not remove tape from the knife when
protecting from cable break.
Operating and Maintenance Manual
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Operating and Installation Instructions - MakroPro 100, MakroPro Alu 100 - installation type STL HLP

When using the lock - use distance sleeves in the side
hinge between the first and second panel.
In gates equipped with lock or bolt it is recommended
to install a lock or bolt sensor.
Removing the keys connecting the shaft with the
servomotor and disassembling the servomotor is only
possible with the gate fully closed.
It is not allowed to operate the gate if there is visible
damage to the drive lines.
8.1. Running maintenance instructions:
8.2. Operations that can be performed by the authorized, trained
personnel having proper qualifications:
8.3. Operations that can be performed exclusively by authorized
service FPHU WIŒNIOWSKI:
Do not block the area of the gate leaf movement.
21. Adjust initially the roller of the first section (fig. 50).
22. Adjust initially the roller of other sections (fig. 50.1).
23. Gate lifting/lowering test (fig. 51).
24. Check correct operation of the electrical protection devices (if used):
photocells - by simulating the operating conditions - after cutting
the light flux the gate should stop and move back,
optical strip - the gate should stop and move back, when the leaf
touches 40 [mm] high object, placed on the floor. If necessary,
adjust and check again, since bad adjustment can result in accident,
lock sensor - when the lock is in locked position the gate should not
start,
pass door sensor - when the door is open the gate should not start.
There is a risk that during installation of the gate some errors can be made,
which can be easily avoided by paying attention that:
vertical guides are properly installed, according to the specification
provided in these instructions,
the closed gate leaf creates equal plane, sections must not show any
deformations - any displacements of the sections should be corrected
on the hinges,
side hinges are adjusted according to the instructions,
end stop are pressed when the gate is open (fig. 26),
all fasteners must be properly tightened.
Failure to follow the above mentioned basic guidelines may cause
problems in correct functioning of the gate, damage to the gate or in
consequence can void the guarantee.
Disassemble the gate in the reverse order as when assembling it.
General proper maintenance conditions for the gate, assuring its long,
trouble-free service:
should you find any malfunctioning of the gate stop using the gate and
contact the authorized service,
do not block the area of the gate leaf movement. When opening and
closing the door leaf make sure that there are no people, especially
children or objects in its way,
do not pass, run or drive under the moving gate, avoid excessive
contamination of the gate leaf, particularly protect the leaf from
harmful elements which could scratch the surface e.g. with sand,
the floor around the bottom washer should ensure free water draining,
protect the gate from contact with any substances harmful to varnish
coatings and metals, ex. caustic substances (acid, lye, salt),
when finishing the room or when renovating it protect the gate from
contact with plaster chips, paints and solvents,
the gate operated electrically should be opened following the
instructions supplied with the electrical equipment,
if during lifting of the gate some excessive resistance is encountered
check correct adjustment of the hinges, if necessary, adjust the hinges
according to the installation instructions,
if pass door are installed in the gate do not lift the gate if the door is not
locked,
after installation (at the latest up to two weeks) remove the protective
foil from the panel surface,
starting the gate when the gate is locked is not allowed.
Operations that can be performed by the client after getting thoroughly
acquainted with the Operating and Maintenance Instructions supplied
with the gate:
for cleaning the gate sections use mild cleansers, safe for varnish
coatings ex. water and soft sponge or cleaning agents intended for use
with varnish coatings available on the market,
for cleaning glazed sections do not use agents containing alcohol or
solvents (may cause dulling of acrylic glass), you can use mild cleaning
agents but we recommend to do some testing first on small glazing
surface,
minimum once per three months and in the case of industrial gates
once a month perform by your own running inspections of the gate to
check the following:
check if the cables are not loose or damaged (broken wires,
corrosion),
check tightening and correct mounting of all fasteners, particularly
screws securing guides, screws securing hinges,
in case of any faults they must be completely removed,
it is not allowed to operate the gate if there is visible damage to the
drive lines,
lubricate the running rollers and hinges at least once every six months
using white mineral oil,
replace the supply batteries at least once every 12 months,
for electrically driven gates check correct adjustment of the limit
switches (check by pressing the corresponding up/down button on the
control panel, observing where the gate stops) - after the gate stops in
closed position the cables should remain stretched, after the gate stops
in open position the bottom gasket should not protrude above the gate
opening,
for electrically driven gates once every month check correct operation
of electrical safety devices (if used):
photocells - by simulating the operating conditions - after cutting
the light flux the gate should stop and move back,
optical strip - the gate should stop and move back, when the leaf
touches 40 [mm] high object, placed on the floor. If necessary,
adjust and check again, since bad adjustment can result in accident,
lock sensor - when the lock is in locked position the gate should not
start,
pass door sensor - when the door is open the gate should not start,
check operation of the emergency opening facility supplied with the
servomotor.
minimum once per six months and in the case of industrial gates once
per three months perform inspections of the gate to check the
following:
check cables on the entire length, for damage (broken wires,
corrosion), check cable fitting on cable drums,
check tightening and correct mounting of all fasteners, particularly
screws securing guides, screws securing hinges, and keys, fastening
of the servomotor,
check proper functionality of devices protecting from cable
breaking,
in the case of errors in work of electrical drives disconnect the drive
from power supply for 2, 3 min and reconnect,
check adjustment of the rollers, adjust if necessary,
check condition of pass doors - adjust if necessary,
any modifications of the gates,
replacement of the protection from cable breaking,
replacement of cables, cable drums,
repairs of electrical components.
When opening and closing the gate leaf make sure that there
are no people, especially children or objects in its way.
Do not allow children to play with the equipment.
Gate control transmitters should be kept out of the reach
of children.
N
N
N
N
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
N
N
N
P
P
P
P
P
N
N
N
N
P
P
N
N
N
N
N
N
P
P
P
P
P
P
6. GATE INSTALLATION ERRORS
7. DISASSEMBLY OF THE GATE
8. MAINTENANCE INFORMATION
9. GATE OPERATING INSTRUCTIONS
in case of any faults they must be completely removed,
all activities should be carried out following the gate operating and
maintenance instructions.
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Operating and Installation Instructions - MakroPro 100, MakroPro Alu 100 - installation type STL HLP
Operating and Maintenance Manual

Prior to first opening the gate check its correct installation.
Electrically driven gate:
I. Operating the gate under normal conditions (without power loss)
without self-support:
II. Operating the gate under normal conditions (without power loss)
with self-support:
III. Operating the remotely controlled gate under normal conditions
(without power loss):
IV. Emergency opening of the gate - manual operation (in case
of supply voltage loss).
Warning! Risk of injury in case of improper use!
Manual emergency start "QUICK CHAIN" or "Emergency manual
chain"
Changing the length of the catch chain
S2K/KNH version
The gate
is mounted correctly if its leaf opens and closes smoothly and the door
can be operated with ease.
1. Opening: press the button and hold it until the gate is completely
open.
2. Closing: press the button and hold it until the gate is completely
closed.
3. The gate is stopped in each intermediate position when the button
is released.
1. Opening: press the button once and wait until the gate completely
opens.
2. Closing: press the button once and wait until the gate completely
closes.
3. The gate is stopped in each intermediate position with the STOP
button.
1. Opening: press the control button once on the remote controller and
wait until the gate completely opens.
2. Closing: press the control button once on the remote controller and
wait until the gate completely closes.
3. The gate is stopped in each position with the control button on the
remote controller.
Manual emergency start is intended for opening or closing of the gate
without electrical power supply.
Before manual emergency start make sure to turn off the main switch of
the drive. Manual emergency start is only allowed with the stopped motor.
With the manual start of the drive position yourself in a safe position.
In the case of servomotors with spring-loaded brake, opening and closing
of the gate must take place by overcoming the brake resistance. For safety
reasons with gates without weight compensation you may only release the
brake for control purposes when the gate is in its lower position.
When using the manual emergency start facility do not set the gate outside
its extremities, since this will activate emergency limit switches. Electrical
actuation of the gate is not possible then.
S1K version: "Quick two chains".
KNH version: "Emergency manual chain".
Actuation of the manual emergency unit is possible with the horizontal
and vertical installation position of the actuator. For other non-standard
installation positions, the actuator must be located within the area, shown
on fig. I. If necessary, fit the element of the manual emergency start
in a position reversed by 180°.
The catch chain can be open in the linking point and shorten or elongate
it using extra chain links. Make sure to carefully overbend the chain
links. When changing the length of the catch chain pay attention not
to twist the chain during installation - fig. II.
"Quick two chains" - fig. III.
"Emergency manual chain"
First, pull slightly the red holder of the activating chain (1) home (maximum
activation force 50 N). Control voltage is off and the gate can be opened
or closed using the catch chain (2) (maximum activation force - see
technical data in the servomotor documentation).
Slight pulling the green holder of the activating chain home (maximum
activation force 50 N) turns the control voltage on, the gate can be
now electrically controlled.
______________________________________
______________________________________
Ç
È
Ç
È
Design and specification are subject to change (resulting from
technological progress) without notice, which do not alter the
functionality of the product.
This documentation belongs to FPHU WIŒNIOWSKI. Copying, duplicating
and using the document in whole or any part of it without owner's written
permission is not allowed.
Please disconnect power supply before using
emergency opening.
Fig. I
Fig. II
Fig. III
(1)
(2)
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Operating and Installation Instructions - MakroPro 100, MakroPro Alu 100 - installation type STL HLP
Operating and Maintenance Manual

5
1.2
24
25
18-22
37
16
40
7-14
39
42
34
32
1
n
Operating and Installation Instructions - MakroPro 100, MakroPro Alu 100 - installation type STL HLP
Operating and Maintenance Manual

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Operating and Installation Instructions - MakroPro 100, MakroPro Alu 100 - installation type STL HLP
Operating and Maintenance Manual
1000 2000 3000 4000 5000 6000 7000 8000
2400
2000
1000
3000
4000
5000
2100
So [mm]
Ho [mm]
A1
A14
A12
A13
A3
A11
A10
A9
A8
A6
A5
A4
A2
A15
2
3
A7

7
W1 W2
N
E
O.K.
44.1
5
4.2
So
600
250
[mm]
Ho
N
E
5.1
5.2
Operating and Installation Instructions - MakroPro 100, MakroPro Alu 100 - installation type STL HLP
Operating and Maintenance Manual

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Operating and Installation Instructions - MakroPro 100, MakroPro Alu 100 - installation type STL HLP
Operating and Maintenance Manual
Æ12
A
B
C
D
Æ8.4
E
Æ10.5
M10
M8
F
6.3x38
G
M8x25
H
M8x20
I
M8x16
K
M10x30
J
M10x25
Æ12
Æ12
6
6.1

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Operating and Installation Instructions - MakroPro 100, MakroPro Alu 100 - installation type STL HLP
Operating and Maintenance Manual
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88.1
9.1 9.2 9.3
So
Console spacing
7
Sz + 300

10
Operating and Installation Instructions - MakroPro 100, MakroPro Alu 100 - installation type STL HLP
Operating and Maintenance Manual
A
10.2
10 10.1
11.1
10.3 10.4 10.5
11
11.2

11
Operating and Installation Instructions - MakroPro 100, MakroPro Alu 100 - installation type STL HLP
Operating and Maintenance Manual
12
12.1 12.2
11.3
A
B
14.1
A
B
AB
13.1
13.2
AB
13
A
B
14
option

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Operating and Installation Instructions - MakroPro 100, MakroPro Alu 100 - installation type STL HLP
Operating and Maintenance Manual
15.3 16
16.1 16.2 16.3
15.1
15.2
15

13
Operating and Installation Instructions - MakroPro 100, MakroPro Alu 100 - installation type STL HLP
Operating and Maintenance Manual
A
B
A=B
E
I
B
16.6
16.7
17
16.4 16.5
16.8
A
16.9 16.10
16.11

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Operating and Installation Instructions - MakroPro 100, MakroPro Alu 100 - installation type STL HLP
Operating and Maintenance Manual
A
18.1
19 19.1
18.2
18
B
A
21
20.1
EG
B
20

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Operating and Installation Instructions - MakroPro 100, MakroPro Alu 100 - installation type STL HLP
Operating and Maintenance Manual
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25
H
BE G
24 24.1
23

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Operating and Installation Instructions - MakroPro 100, MakroPro Alu 100 - installation type STL HLP
Operating and Maintenance Manual
Automatic drive
26
25.2
BEH
25.3 25.4
25.1

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Operating and Installation Instructions - MakroPro 100, MakroPro Alu 100 - installation type STL HLP
Operating and Maintenance Manual
32 33
29
27
Servomotor version SI 55
30.1
30
28

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Operating and Installation Instructions - MakroPro 100, MakroPro Alu 100 - installation type STL HLP
Operating and Maintenance Manual
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37
36 36.1
38
35
Servomotor version SI 17, SI 25, SI 40
1
2
SI 40
SI 40

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Operating and Installation Instructions - MakroPro 100, MakroPro Alu 100 - installation type STL HLP
Operating and Maintenance Manual
F
39
40 40.1
38.1
After installing the cable on the safety brake fit the cotter pin!
41.4
41 41.1 41.2
41.3
min. 3
turns

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Operating and Installation Instructions - MakroPro 100, MakroPro Alu 100 - installation type STL HLP
Operating and Maintenance Manual
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46.1
45
47
44
44.1
43.1
42
F
43