1

CE DECLARATION OF MACHINE CONFORMITY(DIRECTIVE 2006/42/EC)

Manufacturer : FAAC S.p.A.

Address: Via Calari, 10 - 40069 Zola Predosa BOLOGNA - ITALY

Declares that: Operator mod. 541 3ph

• isbuilttobeincorporatedintoamachineortobeassembledwithothermachinerytocreateamachineundertheprovisionsofDirective2006/42/EC;

• conformstotheessentialsafetyrequirementsoftheotherfollowingEECdirectives:

2006/95/ECLowVoltagedirective. 2004/108/ECElectromagneticCompatibilitydirective

andalsodeclares that it isprohibited toput into service themachineryuntil themachine inwhich itwillbe integrated or of which it will become a component has been identified and declared as conforming totheconditionsofDirective2006/42/EC.

Bologna,01January2011 TheManagingDirector A.Marcellan

1) ATTENTION! To ensure the safety of people, it is important that you read all the following instructions. Incorrect installation or incorrect use of the product could cause serious harm to people.

2) Carefullyreadtheinstructionsbeforebeginningtoinstalltheproduct.

3) Donot leavepackingmaterials (plastic,polystyrene,etc.) withinreachofchildrenassuchmaterialsarepotentialsourcesofdanger.

4) Storetheseinstructionsforfuturereference.

5) Thisproductwasdesignedandbuiltstrictlyfortheuseindicatedinthisdocumentation.Anyotheruse,notexpressly indicatedhere,couldcompromisethegoodcondition/operationoftheproductand/orbeasourceofdanger.

6) FAACdeclinesallliabilitycausedbyimproperuseoruseotherthanthatforwhichtheautomatedsystemwasintended.

7) Donotinstalltheequipmentinanexplosiveatmosphere:thepresenceofinflammablegasorfumesisaseriousdangertosafety.

8) ThemechanicalpartsmustconformtotheprovisionsofStandardsEN12604andEN12605.

For non-EU countries, to obtain an adequate level of safety, theStandardsmentionedabovemustbeobserved,inadditiontonationallegalregulations.

9) FAAC is not responsible for failure to observe Good Technique intheconstructionoftheclosingelementstobemotorised,orforanydeformationthatmayoccurduringuse.

10) TheinstallationmustconformtoStandardsEN12453andEN12445. For non-EU countries, to obtain an adequate level of safety, the

Standardsmentionedabovemustbeobserved,inadditiontonationallegalregulations.

11) Beforeattemptinganyjobonthesystem,cutoutelectricalpower.

12) Themainspowersupplyoftheautomatedsystemmustbefittedwithanall-poleswitchwithcontactopeningdistanceof3mmorgreater.Useofa6Athermalbreakerwithall-polecircuitbreakisrecommended.

13) Makesure thatadifferential switchwith thresholdof0.03A is fittedupstreamofthesystem.

14) Makesurethattheearthingsystemisperfectlyconstructed,andconnectmetalpartsofthemeansoftheclosuretoit.

15) The safetydevices (EN12978 standard) protectanydangerareasagainstmechanical movement Risks,suchascrushing,dragging,andshearing.

16) Useofatleastoneindicator-light(e.g.FAACLIGHT)isrecommendedforeverysystem,aswellasawarningsignadequatelysecuredtotheframestructure,inadditiontothedevicesmentionedatpoint“15”.

17) FAACdeclinesallliabilityasconcernssafetyandefficientoperationoftheautomatedsystem,ifsystemcomponentsnotproducedbyFAACareused.

18) Formaintenance,strictlyuseoriginalpartsbyFAAC.

19) Donotinanywaymodifythecomponentsoftheautomatedsystem.

20) Theinstallershallsupplyallinformationconcerningmanualoperationofthesystemincaseofanemergency,andshallhandovertotheuserthewarningshandbooksuppliedwiththeproduct.

21) Do not allowchildren or adults to stay near theproductwhile it isoperating.

22) Keepremotecontrolsorotherpulsegeneratorsawayfromchildren,topreventtheautomatedsystemfrombeingactivatedinvoluntarily.

23) Transitunderthedoorispermittedonlywhentheautomatedsystemisidle.

24) Theusermustnotattemptanykindofrepairordirectactionwhateverandcontactqualifiedpersonnelonly.

25) Maintenance:checkatleastevery6monthstheefficiencyofthesystem,particularlytheefficiencyofthesafetydevices(including,whereforeseen,theoperatorthrustforce)andofthereleasedevices.

26) Anything not expressly specified in these instructions is not permitted.

WARNINGS FOR THE INSTALLERGENERAL SAFETY OBLIGATIONS

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AUTOMATED SYSTEM 541 3ph

2. DIMENSIONS AND DESCRIPTION

1. TECHNICAL SPECIFICATIONS

Power supply (Vac 50-60Hz) 400(+6–10%)Electric motor 3-phaseinduction1450rpmMaximum absorbed power (W) 720Absorbed current (A) 1.1 Starting capacitor (µF) 20Winding thermal protection (°C) 140Use frequency (S3) ROT 60% Max number consecutive cycles 6Power take-off Hollowthroughshaftdiam.25,4mm(1’’)Power take-off rotation speed (rpm) 23Rated torque of power take-off (Nm) 70 Power take-off max revs 24Protection class IP54Operating ambient temperature (°C) -20/+55Gearmotor max weight (Kg) 14 Type of oil FAACXD220Oil quantity (l) 0,9

Note: consult Table 1 for chain transmission applications

Graph 1

Table 1

Type of Rated Rope shaft Rope shaft application torque speed max revs (Nm) (rpm) Direct 70 23 24 Reduction ratio 1:1.5 105 17,2 18 Reduction ratio 1:2 140 11,5 12

Transmission 1:2

Transmission 1:1.5

Direct application

Theseinstructionsapplytothefollowingmodels:

FAAC 541 3ph

The5413phautomatedsystemisdesignedforautomatingbalan-cedindustrialsectionaldoors.Theyconsist ofanelectro-mechanical operator,withon-board(541D)inter-connectionboard,forremotecontrolunit(844T).Installationispossibleeitherdirectlyontheshaftoftherope-windingdrums,orbychain transmission (optional item)witha reductionratioof1:1.5or1:2.Thenon-reversingsystemensuresmechanicallockingofthedoorwhenthemotorisnotoperatingand,therefore,nolockneedstobeinstalled;themanualreleaseandthemanualopeningsystem(inmodelsforwhichitissupplied)makeitpossibletomovethedoorincaseofapowercutormalfunction.The 541 3ph automated systems was designed and built for indoor and outdoor use.

Graph1showswithwhichtypeofapplication the5413phcanbeinstalled,consideringthemaximumforcerequiredtomanuallymovethedoorF, indaN(1daN= force required to lift1,02kg),andthediameteroftherope-windingdrumDt inmillimetres.Forexample, ifadoorcanbemovedwithaforceof108daNandthedrumdiameteris180mm,a5413phwithchaintransmissionof1:1.5mustbeinstalled.N.B.ForceFcanbemeasuredwithadynamometer.Itisnotdirectlyrelatedtotheweightofthedoor,buttoitsbalance.

Fig. 1

F (d

aN

)

Dt (mm)

3

3. ELECTRICAL EQUIPMENT ARRANGEMENT

Figure3showsthelayoutoftheelectricalequipmentrequiredforinstallingthe5413phoperatorwith844Tremoteequipment.

4. PRELIMINARY CHECKS

Thedoor structuremustbesuitable tobeautomatedandmustconformtostandardsEN12604andEN12605.Theropewindingshaftmusthaveakeyway.Itmustprojectlaterallybyawidth sufficient to install theoperatorand thekey lockingcollars(operatormounteddirectlyonshaft)ortosecurethecrown-gear(mountingwithchaintransmission-optionalitem).Somedoormanufacturerssupplyspecialjointswithshaft,whichmakesitpossi-bletomotorisedoorswhichwerebuiltwithouttherequiredfacility.Checktheefficiencyofbearings,wheels,parachutesystem,doorrailandjoints.Alsomakesurethatthetractionropesareperfectlyfittedinthegroovesofthedrums,donotcomeintocontactwithmechanicalpartsorfixedpartsofthestructure,andaresubjectedtothesamedegreeoftension.Makesurethatthereisnofrictiononthedoor:thedoormustslidesmoothlywhenbothopeningandclosing.Check if thedoor iswellbalanced: if stopped inanyposition, itmustremainstill.Remember thatEuropeanstandardsEN12604andEN12453pre-scribe260N,formanuallymoveddoors,asthemaximumlimitofforceapplied to thehandles formanualmanoeuvre,and390Nformotoriseddoors.Consultthetechnicaldocumentationofthedoortofindouttheshafttorquerequiredformovementandthenumberofrevsne-cessaryforcompleteopening.Consulttable1toseewhichtypeofinstallation(directlyonshaftorchaintransmissionwithreduction)satisfiesthedeclaredspeci-

Fig. 2 Fig. 3

Powercabling-5x1.5(4xPowersupply400Vac+Earth) Powercabling-4x1.5(3xMotorpowersupply400Vac+Earth)+2x0.5flashinglamp Lowvoltagecabling-controlsforequipment+safetyedge Lowvoltagecabling-4x0,5Rxphotocells Lowvoltagecabling-2x0.5Txphotocells Lowvoltagecabling-radioreceiver Lowvoltagecabling-6x0.5controlpanel Equipmentenclosure

Operator Powertake-offSecuringplateLimit-switchunitWinch(inmodelsforwhichitissupplied)Equipmentenclosure ReleaseleverKeysecuringbushesKeySecuringplate3D(optionalitem)

fications.Theefficiencyand safetyof theautomated systemarecloselylinkedtotheabove.Youthereforemustgetintouchwiththedoormanufacturerorinstallerifyouencounteranyproblems.Removethedoormechanicalclosurestoensurethedoorislockedbytheautomatedsystem.Removethemanualactivationdeviceifsup-plied.Checkifanefficientearthingsystemisavailableforelectricalconnectiontotheoperator.

5. INSTALLING THE OPERATORToworkundersafeconditions,weadviseyoutoinstalltheoperatorwhilekeepingthedoorfullyclosedandtoreadthewholeofthischapterbeforestartingtoinstall.The5413phoperatorhasa25.4mm(1”)powertake-off.Ifthedri-veshaftisofadifferentsize,thechaintransmission(optionalitem)mustbeinstalled.Themanualactivationdevices(releaseandchaindrive)aredesig-nedforinstallationataheightofupto4metres.Toinstallatgreaterheights,usetheextensionkits(optionalitems).Theoperatorisequippedwithfourmicroswitcheswiththefollowingfunctions:•Openinglimit-switch•Closinglimit-switch•Winch safety switch (onlyonmodels suppliedwith themanualmanoeuvringsystem)•ReleasecontrolsafetyswitchThesuppliedsupportplatewillenableyoutosecuretheoperatoratamaximumdistanceof125mmbetweentheanchoringpoint(wallormetalstructure)andthepowertake-offaxis.Beforeinstalling,weadviseyoutochecktherotationdirectionofthepowertake-off(seeparagraphs5.7).Forallmattersreferringtotheelectricalsystem,pleaseconsultthechapterentitled“Warningsfortheinstaller”andchapters3and6oftheseinstructions.ThesuppliedCordurahandlecanbeinstalled,usingtheplatefa-steningpoints,ontheoperator,tofacilitatetheshiftingoperationsduringthepreliminarystagesofinstallation.

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5.1 OPERATOR WORK POSITIONTheoperator - suppliedwithachain-operatedmanualmotiondevice-mustbeinstalledinthepositionshowninfigure4.Intheabsenceofthewinch,theoperatorcanbeinstalledinanyposition.Ifyouwishtoinstalltheremotereleasecontrol,firstcheckthatthereleaseleverdoesnotinterferewiththeoperator’sexternalparts.Thesecuringplatecanbeinstalledonanyoftheoperator’stwosides.

5.3 INSTALLING THE OPERATOR

•Releasetheoperatorwiththeappropriatelever.•Fitthesecuringplateontheoperatorwithouttighteningthescrews.•Engagethepowertake-offonthedriveshaft.•Positiontheoperator(seeparagraph5.1)andresttheplateonthesupport(wallormetalstructure)onwhichyouhavedecidedtosecureit(seefigure6.).•Tightenthescrewswithout forcingthem,while restingtheplateonthesupport.

•Tracethepositionoftheinstallationholes.•Removetheoperator.•Carryoutthesecuringpreparationwork.•Insertthefirstkeysecuringbushandthekeyitselfintheshaft(seefig.2ref.8and9).•Re-installtheoperatorwiththeplatereleased.•Securetheplatetothesupport,tightenthefasteningscrewsontheoperatortoamaximumtorqueof18Nmandinsertthesecondkeysecuringbush.•Securethetwobushesafterpositioningthemincontactwiththeoperator’spowertake-off.•Locktheoperator.Ifyouwishtoweldthesecuringplatetothesupport,dothewel-dingwiththeoperatoruninstalled,andprotectthedriveshaft inthepowertake-offengagementzone.Iftheoperatorcannotberemoved,itmustbeprotected.

Fig. 6Fig. 4

5

Fig. 7

Fig. 8

5.4 WINCH ADJUSTMENT

Unwindthesuppliedchaincompletelyandjoinoneofititsendstotheonealreadyfittedtothewinch,withoutcuttingtheserviceclip.Useoneofthesuppliedlinks,selectingfromthoseinsteel(seefigure7ref.A)orfromthoseinplastic(seefigure7ref.B).Theplasticlinksmustbeassembled.Tightenthesteellinksaccura-tely,toallowthechaintomoveperfectly,insidethewinch.Cutthechaintosize,withoutallowingthelowerpartoftheringitformsfromtouchingthefloor,andmakingsurethatitiswoundarounditself(seefigure8).Assembletheothersideofthechain,inthesamewayasinfigure7.Cuttheservicecliponlywhenthechainisinstalled.Adjustthescrewofthebalancingspring(seefigure9)sothatthewinchsupportdisappearscompletelyinsidetheplasticenclosure(seefigure10).Checkifthetractionofjustoneofthechainsectionscausesthewinchtoengageand,ifthewinchreturnstoitsidlepositionwhenit is released.Tightenthesecuringnutandmakesurethatoperatoractivationisnotinhibitedorinterruptedbythetrippingofthewinchsafetymicroswitch.Weadviseyoutoprovideananchoringpointforthelowerpartofthechainsothatitcannothinderthetransitofpeopleorofope-ratingmeans.Applythestickerindicatingtheopeningandclosingdirections,inaclearlyvisibleway.If youareusing thechainextension kit, replace thebalancingspring (fig.9 ref.3)with theonecontained in thekit. If youareusingplastic joints,weadviseyoutogluethemtogetherduringassembly(seefig.7ref.B).

ref.A

Fig. 9

WinchsupportAdjustmentscrewandfasteningnutChainbalancingspring

Fig. 10

ref.B

6

FC2

FC1

DIR2DIR1

5.6 ADJUSTMENT OF LIMIT-SWITCH UNITTheprocedureforadjustingtheclosingandopeninglimit-switchisasfollows:Completelyclosetheindustrialsectionaldoor.Usingtrimmer1,withthearrowfacingdown(closing),turnclockwiseto+oranti-clockwiseto-untiltheclosinglimit-switchisactivated.Thensettheindustrialsectionaldoorinopeningposition.Usingtrimmer1,withthearrowfacingup(opening),turnclockwiseto+oranti-clockwiseto-untiltheopeninglimit-switchisactivated(seefig.11).Noteforfineadjustment:the“+”symbolindicatesbackingawayoftheactivatorfromthemicroswitchandthereforealongerstroke;the“-”symbol,onthecontrary,indicatesitsapproachandconsequentlyashorterstroke.Finalcheckoftheopenandclosedpositions.Manuallymovethedoorinopenandcloseposition.Ensurethattheoperatoractuallyreachesthedesiredpositionswhenopeningandclosing.Ifthisdoesnotoccur,correctthelimit-switchpositionsusingtrimmer1.Ifusedwith578Dequipment,youcancorrecttheclosingstoppointalsobyvaryingthepost-endoftraveldeceleration.

Fig. 11

Limit-switchtrimmerupanddownadjusting microswitchlimit-switchupanddown

5.7 IDENTIFYING ROTATION DIRECTION (operator with 844T equipment)

Figure12showsrotationdirectionsDir1andDir2.MotioninDir1directionisstoppedbyFC1andmotioninDir2directionbyFC2.Consequently,if,forexample,Dir2istherotationdirectioncausingthedoortoclose,FC2deter-minesthestopclosingpointandFC1determinestheopeningstoppoint.TheOPENcommandisnormallyassociatedwithDir1motion-consulttheequipmentinstructionsiftherotationdirectionshavetobereversed.Thestopspringofthering-nutsactivatingthelimit-switches,iskeptliftedupbythesquare-thelattermustnotberemoveduntilthedoorstoppointsareadjusted.

Fig. 12

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5.8 INSTALLING THE REMOTE RELEASE LEVERCarryouttheoperationswiththedoorclosed.Cutthedriveropestomeasureandassemblethemwiththeleverandknobs(seefigure15),bearinginmindthatthegreenonemustactonthelever’sshortarm.Infigure16,thetwosideviewsshowthepositionoftheleverwithlockedoperator,andtherelevantpositionsofthereleaseropes(withredknob)andlockingropes(withgreenknob).Fittheleverandmakesurethatitreachesthetravellimitsinthetwodirections,ataninclinationofabout45-50°.Fittheleverfixingscrew.Makesurethattheremotemanoeuvreiscorrectandthat,whentheoperatorisinlockedposition,itisnotpreventedfromoperatingbythereleasesafetymicroswitch.

Opening

Closing

Increase stroke

Reduce stroke

Reduce stroke

Increase stroke

Fig. 13

Fig. 14

8

7. START-UP Whenyouhavecarriedoutalltheelectricalconnections,lockedtheoperator,andcheckedthat thedoorcannotbemovedbyhand,powerupthesystem.Iftheoperatorissuppliedwithawinch,fix-intheimmediatevicinityofthechain-thestickerindicatingthetractiondirectionsfortheopeningandclosingmanualmanoeuvres.

7.1 541 3ph WITH 844T EQUIPMENT

Programtheunit,followingtheinstructionsofthe844Tunit.

6. ELECTRICAL SYSTEMATTENTION: Before attempting any work on the board (connections, maintenance), always turn off power.Thespecificationsoftheelectricalsystemareincludedinthechap-ter“Warningsfortheinstaller”.Alwaysseparatepowercablesfromcontrolcables.The5413phoperatorissuppliedwithanon-boardinter-connectionboard.

6.1 CONNECTIONS OF 844T ELECTRONIC EQUIPMENT

Laytheracewaysaccordingtotheinstructionsinfigure4.Maketheconnectionsbetweenthe844Tunitandthe541Dinter-connectionboard,installedontheoperator,followingthediagraminfigure17.ASTOPpush-button,ifany,mustbelocatedinserieswithrespecttotheconnectionbetweentheSTOPinputof844TandtheSAFETYofthe541DINTERFACE.Forwiring,andforprogrammingthe844T,refertotheinstructionsfortheunit.

Fig. 17

8. MAINTENANCEMaintenance:checkatleastevery6monthstheefficiencyofthesystem,particularlytheefficiencyofthesafetydevices(including,where foreseen, theoperator thrust force)andof the releasedevices.

9. REPAIRSForrepairscontactanauthorisedFAACRepairCentre.

Releaseknob(red)Lockingknob(green)

Fig. 15

Fig. 16

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USER’S GUIDE

541 3ph AUTOMATED SYSTEMSReadtheinstructionscarefullybeforeusingtheproductandstorethemforfutureuse.

GENERAL SAFETY REGULATIONSIfcorrectlyinstalledandused,5413phautomatedsystemsensureahighdegreeofsafety.Somesimplerulesonbehaviourcanpreventaccidentaltrouble:-Donot,underanycircumstances,standunderthesectionaldoor.-Donotallowchildren,personsorthingstostandneartheautoma-tedsystems,especiallywhiletheyareoperating.

-Keepremote-controls,orotherpulsegeneratorsthatcouldopenthedoor,wellawayfromchildren.

-Donotallowchildrentoplaywiththeautomatedsystem.-Donotwillinglyobstructdoormovement.-Preventanybranchesorshrubsfrominterferingwithdoormove-ment.

-Keepwarning-lightsefficientandeasytosee.-Donotattempttoactivatethedoorbyhandunlessyouhave

released it.-Makesurethattherearenopersons,animalorthingsnearthedoorbeforereleasingthedoor.

- In theeventofmalfunctions,manuallyactivateor release thedoortoallowaccessandwaitforqualifiedtechnicalpersonneltodothenecessarywork.

-Whentheoperatorisreleased,beforerestoringmotorisedopera-tion,makesurethatthesystemisnotpowered.

-Donot inanywaymodify thecomponentsof theautomatedsystem.

-DonotattemptanykindofrepairofdirectactionwhateverandcontactqualifiedFAACpersonnelonly.

-Atleasteverysixmonths:arrangeforqualifiedpersonneltocheckefficiencyof theautomated system, safetydevicesandearthconnection.

-Arrangeforqualifiedpersonneltocheckthedoorattheintervalsrecommendedbythemanufacturer,addressingspecialattentiontothesafetysystemsandbalancing.

- Transit under thedoor ispermittedonlywhen theautomatedsystemisidle.

DESCRIPTION

The5413phautomatedsystemsareidealforactivatingbalancedindustrialsectionaldoors.They consist of an electro-mechanical operator and remoteelectroniccontrolequipment. Thenon-reversing systemensuresmechanicallockingofthedoorwhenthemotorisnotoperatingand,therefore,nolockneedstobeinstalled.Operatorreleaseandamanualmanoeuvringsystem(thelatterisonlysuppliedonthemodelsforwhichitisspecified),makethedoormanoeuvrableintheeventofapowercutormalfunction.Thedoor is normallyclosed;whenopening iscommanded, theequipmentactivatestheelectricmotorwhichdrivesthedoortoopeningposition topermitaccess. In “dead-man” systems, thecommandpush-buttonmustbekeptpressedforthewholedurationoftheopeningorclosingmanoeuvre.Intheautomaticallyoperatingsystems:-Iftheautomaticlogicwasset,thedoorclosesafterpausetimehaselapsed.

-Ifthesemi-automaticlogicwasset,asecondpulsemustbesenttoclosethedoor.

-Astoppulse(ifsupplied)alwaysstopsmovement.For fulldetailsonthebehaviourof theautomatedsystem inthedifferentlogics,consulttheinstallationTechnician.Automatedsystemsmayincludesafetydevices(sensitiveedges,photocells)thatpreventthedoorfromclosingand/oropeningwhenthereisanobstacleintheareatheyprotect.Emergencymanualopeningispossiblebyusingthereleasesystem.

Manualcommandispossiblebyactivatingthechain-operatedwinch(formodelswithwhichitissupplied).Electriccommandisdisabledduringthemanualmanoeuvreorwhentheoperatorisreleased.Thewarning-light,wheresupplied,indicatesthatthedooriscur-rentlymoving.

MANUAL OPERATION (541 3ph with winch)

If thedoor has tobeactivatedand theautomated system isinactiveduetoapower-cutormalfunction,thedooropeningandclosingmanoeuvrescanbedonebyhand,byusingthechain-operatedwinch.Checktheindicatorsigntoseewhichbranchofthechainhastobeactivatedtoperformtherequiredmanoeuvre.Pulldownwardonlythebranchinvolved.Ifnoindicatorsignispresent,pulloneofthechainbrancheswi-thoutforcingandcheckifthedoortendstomoveintherequireddirection.Ifnot,activatetheotherbranch.Whilethewinch isoperating,theoperator’selectricalcontrol isdisabled.

RELEASING THE OPERATOR AND RESTORING AUTO-MATIC OPERATION

The5413phoperatorsareprovidedwithanemergencysystemwhichcanbeactivatedfromtheinside.Theoperator releaseoperationmustbeeffectedwiththedoorclosedifpossible.Inanyevent,thepresenceofpersons,animalsandobjectsintheimmediatevicinityoftheoperatorisabsolutelyforbidden.Ifthedoorhastobemovedmanuallyduetoapowercutormal-functionoftheautomatedsystem,cutoutpowertothesystemandusethereleasedeviceasfollows:releasetheoperatorbypullingtheropewiththeredknob(seefigure1)downwarduntiltheleverreachesthetravel-limitstop.Torestoreautomaticoperation,fullyclosethedoorandpulltheropewiththegreenknobuntiltheleverreturnstoitsoriginalposition.

Fig. 1