GB INSTALLATION MANUAL
APROLI 480 OIL-HYDRAULIC OPERATOR FOR GARAGE DOORS SECTION VIEW OF THE OIL-HYDRAULIC OPERATOR WITH LAMP AND COVER UPPER SECTION SUPPORT LAMP REFLECTOR LIGHT DIFFUSION COVER 230 V-25 W LAMP SCREW SEAT FOR FIXING THE COVER/UPPER SECTION ELECTRIC TERMINAL COVER OIL CONTAINER ELECTRIC TERMINALS ELECTRIC MOTOR TOP END CAP FADINI OIL A 15 BY AGIP HYDRAULIC LOBE PUMP S AIR BLEED SCREW O.33 HP ELECTRIC MOTOR OIL RESERVOIR TWO-WAY LOCKING VALVE PRESSURE VALVE ASSEMBLY C A B FADINI OIL A 15 BY AGIP MANUAL RELEASE LEVER TWO-WAY LOCKING VALVE ASSEMBLY PISTON SLEEVE FADINI OIL A 15 BY AGIP GEAR BOX HOUSING 1 st PISTON WITH STEEL INSERT TOOTHED SHAFT SHAFT SUPPORT SPACER BEARING/ GEAR TEETH RACK COVER 2 nd PISTON WITH STEEL INSERT SCREW SEAT FOR FIXING THE COVER/BOTTOM END FADINI OIL A 15 BY AGIP BOTTOM SECTION CYLINDER END CAP PIC. 1 2
INSTRUCTIONS FOR THE INSTALLATION OF APROLI 480 TO A GARAGE DOOR WITH COUNTERWEIGHTS WEATHER STRIP DOOR HANDLE WALL FRAME DOOR JAMB COUNTERWEIGHT WHEEL DOOR UPPER EDGE GARAGE DOOR GUIDE ARM TELESCOPIC ARM LATERAL SUPPORT COUNTERWEIGHT COUNTERWEIGHT CASE WEATHER STRIP APROLI 480 WITH COVER BOTTOM DOOR WHEEL WEATHER STRIP 100x5 mm REINFORCEMENT PLATE TO BE FIXED TO THE DOOR FRAME FIXING BRACKET M PIC. 2 No change to the existing door is required for the installation of this operator. Automatic or semi-automatic operations. Hand operation can be made possible by releasing the system through the lever B both from inside or outside the building. (Pic.1) ESSENTIAL COMPONENTS FOR THE APPLICATION OF THE OPERATOR ON TO A GARAGE DOOR HAVING COUNTERWEIGHT (PIC.3) TERMINAL BOARD COVER TELESCOPIC ARM AIR BLEED S TRANSMISSION BAR WITH SHAFT FITTING SLEEVE (SQUARE HOLE) WELDED TO IT TELESCOPIC ARM MAX. PRESSURE SAFETY VALVE OPEN. RED A TRANSMISSION BAR LATERAL SUPPORT FIXING M BRACKET MAX. PRESSURE SAFETY VALVE CLOSE. GREEN C PIC. 3 3
It is recommended to follow the drawings in this manual to install APROLI 480 on to garage doors in order to automate them. The operator is designed for the installation in the centre of the existing door by means of a bracket M that is fixed to the door with screws. Pic.4 15 DOOR FRAME WALL FRAME DOOR JAMB DOOR GUIDE ARM OF THE EXISTING DOOR FIXING M 2 500 COUNTERWEIGHT CASE AND ROLLER GUIDE TUBE PERPENDICULARLY FITTED REINFORCEMENT PLATE 100x5 mm 3 000 PIC. 4 Should the upper and lower fixing ends of the bracket M not coincide with the upper and lower edges of the door, it is recommended to rivet, screw or spot weld an iron reinforcement plate (100 mm - 5 mm thickness) vertically across the door so to connect the top and bottom edges of the door as shown in pic. 4 15 90 TELESCOPIC ARM TO BE PARALLEL FIXED TO THE EXISTING DOOR ARM 20 FIXING PLATE TO WELD 90 80 60 60 REINFORCEMENT OPEN APROLI 480 CLOSED DOOR POSITION 100 x 5 DOOR JAMB/ COUNTERWEIGHT CASE PIC. 5 Once the bracket M has been fixed, it is to be determined whether the telescopic arms are to overlap the existing door arms or be fixed parallel to them. See pic. 5 and 6. Then proceed to weld the fixing plates as indicated by the distances in pic.5 4
40 40 TELESCOPIC ARM OVERLAPPING THE DOOR ARM WHEN THERE IS NO SPACE BETWEEN ARM AND COUNTERWEIGHT 5 EXISTING GUIDE ARM FIXING ABOVE THE ARM PIVOT FIXING ON TO THE GUIDE ARM OPERATOR IN THE OPEN POSITION 40 BRACKET M TELESCOPIC ARM OVERLAPPING THE DOOR ARM WHEN THERE IS NO SPACE BETWEEN ARM AND COUNTERWEIGHT 10 FIXING ON TO THE GUIDE ARM PIC. 6 Once the bracket and the operator have been fixed to the door, proceed to temporarily fix the two telescopic arms to the torsion shaft, considering that the shaft must be allowed to rotate 5 degrees less than the end of the permitted stroke, as further explained in pic.7 END OF PISTON STROKE WHEN NO FURTHER TURNING IS ALLOWED HYDRAULIC LOCKING/ UNLOCKING LEVER B ROTATE IN THE ARROW DIRECTION BY 5 mm TO GET 5 5 5 mm PIC. 7 Rotate the shaft to the end of the permitted stroke by means of pliers. Then rotate the shaft back by 5 mm. This allows more power to the operator when it is required to close the door. Pic. 7. Please note the door must be in closed position when this operation is done. 5
CLOSED DOOR FIXING PLATE TELESCOPIC ARM B LEVEL LEVEL LATERAL SUPPORT LATERAL SUPPORT PROVIDED WITH THE EQUIPMENT TORSION BAR PIC. 8 Fit the two telescopic arms to the torsion bars and make sure that they are perfectly perpendicular to them at the same distance from the door. Adjust the two supports to achieve the above and put some wooden spacers to bring the lateral supports to the required distance. A spirit level will ensure that the torsion bars are perfectly horizontal. See pic. 8. The lever «B» must be in the released position. FIXING PLATE TELESCOPIC ARM WITH SLIDING BAR TELESCOPIC ARM WITH SLIDING BAR CUT TO MEASURE AND WELD LEVEL LEVEL CUT TO MEASURE AND WELD LATERAL SUPPORT TORSION BAR WITH SLEEVE CIRCULAR WELDING PIC. 9 Fit the two telescopic arms and the torsion bars in the correct position and make sure that they are levelled and parallel, door in the closed position. Partially weld the torsion bars to the lifting arms and operate the door by hand. Verify that it can open fully in a quiet and smooth way. The lever «B» in the released position. Pic.8. 6
Once satisfied that the installation is correct and smooth, remove the two torsion bars and the sliding bars in order to firmly fix them by welding all around. Pic.9 FIX THE COVER ONLY AFTER COMPLETING THE INSTALLATION IN THIS POSITION THE DOOR MUST BE WELL BALANCED. SHOULD IT NOT, ADD SOME EXTRA COUNTERWEIGHT 45 PIC. 10 A good test to verify how well balanced the door is in both directions, ie. lifting and lowering, is to position it 45 degrees from ground level, as shown in picture 10. Add counterweight to improve running smoothness and balance if required. MAXIMUM PRESSURE VALVE OPEN RED IN COLOUR A S B AIR BLEED RELEASE LEVER TURN IT ANTI-CLOCKWISE The two safety pressure valves are identified by colours: «A» Open is red; «C» close is green. They are located in the front of the motor/pump unit, easy to reach for setting operations in order to meet the power requirements.pic.11 Once the valves are set, you can fit the cover and the other accessories. Pic.10 MAXIMUM PRESSURE VALVE CLOSE GREEN COLOUR C MORE POWER LESS POWER The setting of the safety pressure valves is to be done so to achieve the exact amout of power required to safely operate the door. The more you turn the screw clockwise, the more you increase the power of the operator. PIC. 11 7
RELEASE LEVER B RUBBER STOP OPEN RECOMMENDED STARTING POSITION BEFORE CLOSE CYCLE RUBBER STOP 25 RUBBER STOP ON THE OUTSIDE OF THE DOOR PIC. 12 The highest power is required to start the close cycle. Therefore it is recommended to fit rubber stops to the door. This will cushion the door at the end of the up stroke and will keep the door inclined by 5 degrees for a better start. See Pic.12. RELEASE LEVER CLAMP B LOCKABLE HATCH DOOR RELEASE CORD DOOR SECTION To release Aproli 480 for hand operations it is available a device as described above, on request. Turn the key sharply; this will pull the cord and the lever open. As an option you can fit the door with a service hatch. Pic.13 HATCH RELEASE LEVER DOOR FROM OUTSIDE PIC. 13 There are two solutions to get access to the operator release lever for hand operations of the door. Either a lock is fitted at a suitable distance from the release lever, to which it is connected by a steel flexible cord as in Pic.13; or a 12 cm x 12 cm lockable hatch is provided and fitted to allow a hand to pass from outside to inside and release the lever «B». 8
The electric cable which supplies power to the motor/pump is connected by means of terminals, which are located above the oil container, next to the earth screw connection. The cable must be led along the door to the point where the telescopic arm is welded to the bar. It is recommended that the cable is allowed to dangle free by 130 cm so that the door can go fully up to the end of the permitted stroke. POSITION OF THE EARTH SCREW CONNECTION ELPRO 6 exp CLOSE OPEN APROLI 480 WITH COVER ELECTRIC CABLE TO DANGLE FREE LENGTH 1.30 METRES PIC. 14 COURTESY LIGHT EXTRA CAPACITOR IN CASE OF POWER SHORTAGE OR TO IMPROVE THE POWER OF THE OPERATOR WHEN HEAVY DOORS ARE INVOLVED TO REVERSE THE DIRECTION OF THE SHAFT ROTATION SWOP WIRES ROUND No. 10 AND No. 12 DO NOT CHANGE No.11 PIC. 15 10 11 12 13 14 ELPRO 6 exp It is essential to make sure that the shaft rotates in the required direction during the first running test. Should it rotate in the opposite direction, change wire No. 10 with No. 12. Pic. 15 9
ELECTRICAL WIRING DIAGRAM OF THE OIL-HYDRAULIC GARAGE DOOR OPERATOR APROLI 480 TO THE ELECTRONIC CONTROL PANEL BIRIO A8 AERIAL RADIO CONTROL PLUG-IN CARD SUPPORT 24 V OUTPUT LED ON VOLTAGE SUPPLIED TRANSFORMER FUSE 630 ma 230 0 meth 8VA 0 24 ASTRO 43/2 RADIO RECEIVER PLUG-IN PC BOARD 1 CHANNEL 1 2 ON OFF MOTOR RUN OPEN & CLOSE TIME DWELL TIME 3 4 ALL OPERATIONS OPEN, STOP & CLOSE RADIO CONTACT 6 exp All the electrical connections to the control panel are to be made as per Drawing 1795 Elpro 6 exp having the following features: terminals for the keyswitch open-stop-close, photocells, safety edge, courtesy light, remote control to terminals 3 & 4 where the first pulse opens the door, the second stops it and the third re-cycles to open or close. 230 V SINGLE-PHASE SUPPLY VOLTAGE 230 V - 25 W MAX. COURTESY LIGHT SINGLE-PHASE MAX. 400W ELECTRIC MOTOR EARTH 24 V OUTPUT A.C. - COURTESY LIGHT FOR TWO MINUTES. ON - FLASHING LAMP. OFF - AUTOMATIC RE-CLOSING. ON - SEMI-AUTOMATIC.OFF Should more pairs of photocells be required than the recommended quantity, fit an auxiliary transformer outside the control box. NOTE WELL: THIS PANEL IS TESTED TO OPERATE GATES ONLY THROUGH FADINI ACCESSORIES. NO GUARANTEE FOR ACCESSORIES OF OTHER MAKE OR SPECIAL APPLICATIONS. MAX. PERMITTED LOAD: 1 PAIR PHOTOCELLS 1 RADIO RECEIVER LIMIT SWITCH. OPEN. N.C. LIMIT SWITCH. COMMON LIMIT SWITCH. CLOSE. N.C. N.O. CONTACT. OPEN SWITCH STOP CLOSE AND RADIO N.C. CONTACT. PHOTOCELLS AND SAFETY EDGE PLUG-IN ASTRO 43 DIP-SWITCH CAPACITOR 12,5 µf 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 M1 FUSES 5 A BUTTON ON THE COVER LID PC BOARD DRWG. 1795 IT IS ILLUMINATED WHEN VOLTAGE IS SUPPLIED STOP OPEN CLOSE COMMON KEYSWITCH PRIT 19 ELECTRICAL CONNECTIONS KEYSWITCH PRIT 19 PIC. 16 10 1 2 3 4 COMUNE 230 V - 25 W MAX. FLASHING LAMP
0 I.T.F. GARAGE DOOR OPERATOR COMPLETE WITH ALL THE RECOMMENDED ACCESSORIES FOR A GOOD PERFORMANCE 1 230 VOLTS MAINS SUPPLY 2 3 1 2 3 4 5 6 7 8 9 1 R1 R2 R2 R1 ASTRO 43 INNESTO 9 NĊ. C N.A. GND ANT. 4 10 5 11 12 6 open 13 7 8 1-0.03 Amp. CIRCUIT BREAKER 2 - MIRI 4 FLASHING LIGHT 25 Watts FITTED WITH BIRIO A8 AERIAL 3 - PLUG-IN RADIO RECEIVER CARD ASTRO 43 SAW 4 - ELECTRONIC CONTROL BOX Elpro 6 exp 5 - START PUSH BUTTON 6 - KEYSWITCH PRIT 19 7 - SAFETY EDGE. LOW PROFILE 8 - PHOTOCELL TRIFO 11. RECEIVER 9-25 Watt LAMP 10 - OPERATOR APROLI 480 11 - COVER TO PROTECT THE VALVES 12 - FIXING BRACKET 13 - PHOTOCELL TRIFO 11. PROJECTOR 14 - RADIO TRANSMITTER ASTRO 43 TWO BUTTONS 14 PIC. 17 11
SPECIAL GARAGE DOORS SAFETY SWITCH 2 500 400 13 CEI SINGLE-PHASE 1.30 m ELECTRIC CABLE TO DANGLE FREE 4 000 REINFORCEMENT PLATE 100x5 mm PIC. 18 When very large doors are involved with a service door in the middle, it is recommended to install two operators Aproli 480 on to the door sides without connecting the shaft inner ends. Fixing dimensions and measurements are as explained before in the previous application drawings. It is also recommended to fit the service door with a safety microswitch as shown in pic.18 When two operators are required for one door, it is recommended to install the control panel Elpro 13 CEI and one pair of photocells Trifo 11. These are to be fixed on to the counterweight case 40 cm from ground level. APPLICATION OF APROLI 480 ON A JACK-KNIFE DOOR 6 exp STEP BY STEP UPPER HINGES CENTER HINGES 80 / 100 mm ELECTRIC CABLE LOOP LENGTH 1.30 m 2 500 SLIDING GUIDE FOR ROLLER REINFORCEMENT PLATE 100 x 5 mm 3 000 PIC. 19 ROLLER WITH SLIDING GUIDE For jack-knife doors, the same instructions apply as for single-panel doors as explained in the previous pages. Only please note that with articulated doors as the above type, it is recommended to fix the operator so that the shaft and the torsion bars are 80-100 mm below the door hinge centre line. Pic.19 12
APPLICATION OF APROLI 480 ON TO A DOOR WITH UPPER TRACK, FULLY INDOOR UPPER FIXING BY THE SIDE OF THE DOOR SLIDING GUIDE WARNING LAMP ON STARTING WITH RADIO AERIAL UPPER GUIDE COUNTERWEIGHT IN THE MIDDLE OF THE DOOR UPPER ROLLER FOR HORIZONTAL UPPER TRACK COUNTERWEIGHT REINFORCEMENT PLATE 100 x 5 mm LOWER ROLLER SLIDING IN THE LATERAL PERPENDICULAR CASING PIC. 20 WALL FRAME For the installation of Aproli 480 on to garage doors with upper track follow the same instructions as explained before; the shaft ie. the torsion fulcrum must coincide with the centre line of the door, right in the middle between upper and lower guide rollers. See Pic. 20 S UNSCREW BY ONE TURN TO BLEED AIR OUT OF THE OIL TANK IMPORTANT AFTER INSTALLATION APROLI 480 UNDO BY ONE TURN S OIL FADINI A 15 BY AGIP STICKER FITTED TO THE OIL TANK PIC. 21 Please note, once Aproli 480 has been fixed, unscrew the air bleed screw by one turn. This screw is fitted on the cap of the oil container, where the voltage supplying cable is led to the motor. Pic.21 Should the operator «Aproli 480» be removed for maintenance or repairing tighten the screw «S» to prevent oil from coming out during handling. 13
UNSCREW LAMP REFLECTOR E PRESSURE SWITCH ELECTRIC CABLE LAMP PIC. 22 ELECTRIC MOTOR VOLTAGE SUPPLY CABLE ELECTRIC CABLE PRESSURE SWITCH SAFETY EDGE WITH PRESSURE SWITCH NEVER CUT THE ELECTRIC CABLES - It is most important that the electric cables are removed from their terminals by loosening the fastening screws. Never cut the electric cables. Also make sure that the 230 V mains switch is off before removing the cables. See page 11 pic. 17. - Only by keeping to these fitting instructions a reliable installation and correct performance of the equipment can be achieved. The installation is fully under the responsibility of the installation agent, even if only Fadini products have been used as indicated in this booklet. It is advisable that the system is installed in full compliance with these instructions and in observance of the existing laws for automatic gate equipment. - The information, specifications and drawings contained herein are subject to any change that the manufacturer considers as needed. 14
OIL-HYDRAULIC OPERATOR FOR GARAGE DOORS WITH COUNTERWEIGHTS APROLI 480 TECHNICAL SPECIFICATIONS APROLI 480 1 2 3 FIXING BRACKET M DOOR OPERATOR LINEAR DESIGN APROLI 480 ELECTRIC TERMINAL OUTPUT 4 LAMP AND LAMP REFLECTOR 5 PROTECTION COVER 6 LIGHT DIFFUSION TOP COVER 7 BOTTOM COVER 91 C 1 2 3 4 600 A APROLI 480 s.n.c. Via Mantova, 177/A - 37053 Cerea (VR) Italy - Tel. 0442 330422 r.a. - Fax 0442 331054 MOTOR W (absor.) VOLTS Rev/min. Nm 2 PHASE 330 230 1 350 392.4 HP (to use) A Hz µf 0.33 1.8 50 12.5 Protection Standards IP 55 Max. working pressure 4 MPa (40 Bar) OIL FADINI A15 BY AGIP MADE IN ITALY DATA STICKER ELECTRIC MOTOR 5 6 1 610 20 x 20 35 180 35 86 86 785 121 7 PIC. 23 OIL-HYDRAULIC PUMP Pump flow rate...1.10 l/min. Working pressure...2 MPa (20 bar) Maximum pressure...4 MPa (40 bar) Working temperature...-20 C +80 C Opening time...18 s Recommended door size...7 m 2 Shaft rotation...max. 205 Hydraulic oil...oil Fadini A15 by Agip Static weight of operator...10.5 Kg Weight of Aproli 480 with accessories...24 Kg Max. torque...392.4 Nm Max. gate weight...150 Kg ELECTRIC MOTOR Power output...0.24 KW (0.33 HP) Supply voltage...230 V Frequency...50 Hz Absorbed power...330 W Absorbed current...1.8 A Capacitor...12.5 µf Motor revolution...1 350 r.p.m. IP Protection Standard...IP 55 Motor rated torque...1.3 Nm Lamp...230 V - 25 W Intermittent service...s 3 PERFORMANCE Duty cycle...18 sec. Opening 30 sec. Dwell 18 sec. Closing Time of one complete cycle...66 sec. Complete cycles...no. 47/hour Annual cycles - 8 hours service per day...no.159 000 15
10-2005 CHECKING AND MAINTENANCE: To achieve an optimum performance and longer life of the equipment and in observance of the safety regulations, it is recommended that inspections and proper maintenance are made by qualified technicians to the whole installation ie, both the mechanical and electronic parts, as well as wiring: - Mechanical parts: maintenance every 6 months approx. - Eletronic apparatus and safety equipment: maintenance every month. IMPORTANT WARNING NOTES - Before installing the equipment carry out a Risk Analysis and fit any required device in compliance with EN 12445 and EN 12453 Safety Norms. - It is recommended to keep to the instructions here outlined. Check the specifications on the motor sticker with your mains supply. - Dispose properly of the packaging: cardboard, nylon, polystyrene, through specializing companies. - Should the operator be removed, do not cut the electric cable. This must be properly removed from the terminal board in the junction box. - Switch off the mains switch before removing the junction box cover where the electric cable is terminated. - All the system must be earthed by using the yellow/green wire, marked by its specific symbol. - It is recommended to read the regulations, suggestions and remarks quoted in the booklet Safety Norms. Made in Italy The growth of MECCANICA FADINI has always been based on the development of guaranteed products thanks to our TOTAL QUALITY CONTROL system which ensures constant quality standards, updated knowledge of the European Standards and compliance with their requirements, in view of an ever increasing process of improvement. The CE mark certifies that the operator conforms to the essential requirements of the European Directive art. 10 EEC 73/23, in relation to the manufacturer s declaration for the supplied items, in compliance with the body of the regulations ISO 9000= UNI EN 29000. Automation in conformity to EN 12453, EN 12445 safety standards. EUROPEAN MARK CERTIFYING CONFORMITY TO THE ESSENTIAL REQUIREMENTS OF THE STANDARDS 98/37/EC DECLARATION OF CONFORMITY SAFETY NORMS EN 12453, EN 12445 STANDARDS CEI EN 60204-1 STANDARDS WARRANTY CERTIFICATE ON THE CUSTOMER S REQUEST AUTOMATIC GATE MANUFACTURERS s.n.c. Distributor s box The manufacturers reserve the right to change the products without any previous notice and are not liable for possible damages to people and properties. Via Mantova, 177/A - 37053 Cerea (Verona) Italy - Tel. +39 0442 330422 r.a. - Fax +39 0442 331054 - e-mail: info@fadini.net - www.fadini.net