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A100/25
en
Assembly and Operating Instructions
Sectional door drives
Important information for:
• Fitters / • Electricians / • Users
Please forward accordingly!
These instructions must be kept safe for future reference.
2349 300 021 0a16/11/2018
Becker-Antriebe GmbH
Friedrich-Ebert-Straße 2-4
35764 Sinn/Germany
www.becker-antriebe.com
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Table of contents
General............................................................................................................................................................................... 3
Warranty ............................................................................................................................................................................. 3
Intended use ....................................................................................................................................................................... 3
Safety instructions ............................................................................................................................................................... 4
Product overview and dimensions ......................................................................................................................................... 6
Installation........................................................................................................................................................................... 7
Emergency manual operation ............................................................................................................................................... 7
Voltage switching............................................................................................................................................................... 11
Electrical connection to the control unit and connection diagram .......................................................................................... 11
Checking the running direction ........................................................................................................................................... 12
Setting the door limit positions ............................................................................................................................................ 12
Maintenance ..................................................................................................................................................................... 13
Technical data ................................................................................................................................................................... 14
Declaration of incorporation................................................................................................................................................ 15
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General
These drives are quality products with many features and advantages.
• Compact design
• Can be installed in any position
• Plug-in control cable
• Universal power supply 3~230 V/400 V/50 Hz
• TÜV type examination – Mark approval certificate in accordance with DIN EN 12453
Please observe these Assembly and Operating Instructions when installing and setting the equipment.
Explanation of pictograms
CAUTION
ATTENTION
CAUTION indicates a hazardous situation which, if not avoided, could
result in injury.
ATTENTION indicates measures that must be taken to avoid damage to
property.
Denotes user tips and other useful information.
Warranty
Structural modifications and incorrect installation which are not in accordance with these and our other instructions can result in
serious injuries, e.g., crushing of limbs. Therefore, structural modifications may only be carried out with our prior approval and
strictly in accordance with our instructions, particularly the information contained in these Assembly and Operating Instructions.
Any further processing of the products which does not comply with their intended use is not permitted.
The end product manufacturer and fitter have to ensure that all the relevant current statutory, official and, in particular, EMC regulations are adhered to during utilisation of our products, especially with regard to end product manufacture, installation and customer advice.
Intended use
The type of plug-in drive featured in these instructions is exclusively designed for indoor use for the operation of sectional doors
whose inherent weight is balanced by springs or a counterweight, or for special applications (only with express approval of the
drive manufacturer).
The plug-in drives must not be used in potentially explosive areas. If the drives are to be used outdoors, special connecting cables
are required; PVC connecting cables must be placed in a protective conduit.
Other applications (e.g., roller doors, vertical lift gates, hoisting devices, awnings, winders), uses and modifications are not permitted in order to protect the safety of the users and others since these actions can impair the system’s safety and carry the risk of
personal injury and property damage. The drive manufacturer does not accept liability for damages or injury arising from such actions.
Always observe the information in these instructions when operating or repairing the system. The drive manufacturer does not accept liability for damage or injury resulting from improper usage.
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Safety instructions
The following safety instructions and warnings are intended to avert hazards and to prevent property damage and personal injury.
General information
• The safety instructions set out in EN 12453, EN 12445, EN 60335, VDE 0100 and ASR A1.7 must be observed.
• Work on the electrical installation, the electrical or electronic systems and units may only be carried out
by a qualified electrician.
• Assembly may only be carried out by a trained and authorised specialist.
• Before using it for the first time, the door system must be inspected by an expert to ensure that it is in a
safe condition.
• Stop the door system and disconnect it from the mains power supply when maintenance and cleaning
is being performed either on the system itself or in the immediate vicinity.
• The national fire and accident prevention regulations must be observed. Suitable protective clothing
must be worn when installing the drive.
• All applicable standards and regulations for electrical installation must be complied with.
• Only use spare parts, tools and accessory devices which have been approved by the drive manufac-
turer.
• Unapproved third-party products or modifications to the system and its accessories represent a risk to
your safety and the safety of others. This means that the use of unapproved third-party products, or
modifications which have not been agreed with or approved by us, are prohibited. We do not accept liability for damage or injury arising from such actions.
• The limits given in the technical data must not be exceeded. The illustrations contained in these instructions are intended as an aid to visualising the product. Therefore, the illustrations may differ from the
actual product.
Caution
Safety instructions for avoiding serious injuries.
• When electrical or electronic equipment and units are operated, certain components are
live. Physical injuries or damage to property can result in the event of unauthorised interventions or failure to heed warnings.
• When installing the drive at a height of less than 2.50 m, the drive must be covered as
contact with the motor could result in burns.
• An adequate clearance distance must be maintained between the drive and combustible
materials.
• When the switches in the safety circuit are open, the control unit being used must switch
off the drive:
- In the case of drives with cam-operated limit switching: safety switches S1F, S2F, S3F,
S4F
- The connection to the control unit must meet Category 2, PL c.
• The door system must be protected against falling.
- In the case of drives for use on roller doors, vertical lift gates, sectional doors and indirectly operated door systems, a suitable mechanism must be provided by the customer
(external safety arrester or anti-unrolling device) in order to reliably prevent the leaves/
door from falling down in the event of failure of the load-bearing medium (e.g. cables or
chains).
- In the case of drives with a light chain (LK) or crank handle (HK), it must be ensured that
the torque acting on the drive is less than the static holding torque stated in the technical
data should the spring break or counterweight fail. If this is not the case, when using
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these drives the door must be prevented from falling down through the installation of an
anti-drop or spring break safety device.
- The signal contacts of the external safety device must comply with PL c.
Operating notes
• Do not allow children to play with permanently mounted regulating or control devices.
• Keep remote control units out of the reach of children.
• Systems have to be checked regularly by authorised specialists for wear and damage. It is forbidden to
use a damaged drive.
• Do not operate equipment if people or objects are within the danger zone.
Caution
If the connecting cable of this unit is damaged, it must be replaced by a qualified person in
order to avoid hazards.
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All dimensions in mm.
Ø 85
Ø 25,4
27,6
6,35
JS9
M 8 x 10
Product overview and dimensions
Drives with a crank handle (HK)
Drives with a light chain (LK)
Hole pattern
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Installation
Caution
Before installing the drive, the driven part must be checked with regard to its mechanical
condition and to ensure smooth opening and closing.
During installation of the drive, access to the danger zone must be blocked off.
The drive must be properly mounted on a mounting or torque supporting plate (in accordance with the output of the drive) with adequate stability.
In the case of directly operated door systems, the drive must be mounted using 4 fastening
screws M8 (8.8) on a vibration reducing mounting.
In the case of indirectly operated door systems, the drive must be mounted using 4 fastening screws M8 (8.8), however should not be mounted on a vibration reducing mounting.
The maximum distance between the drive and chain wheel gearing must not exceed 50
mm.
Assuming a screw-in depth of 10 mm, the tightening torque of the fastening screws for securing the drive must be at least 20 Nm and no more than 25 Nm. Failure to observe this
may result in damage to the product or objects in the immediate vicinity.
Once the sectional door has been mounted and properly counterweighted, the door must be counterweighted in every position.
The correct counterweight is manually adjusted by opening and closing the door.
When installing the drive, always ensure that the drive is protected against soiling (e.g., drilling dust).
Before mounting the sectional door drive on the door shaft, the latter must be lubricated in the drive area.
Attention
Only one of the two feather keys supplied, which is fitted according to the form of the barrel, must be used with these drives. After fastening the drive, the feather key must be secured from moving using the screw supplied.
Feather key for 1" tubular shaft Feather key for 1" solid shaft
Emergency manual operation
Emergency manual operation is only intended for commissioning the drive, maintenance work and emergency operation in order
to open or close the door in the event of a short-term power failure. Emergency manual operation is solely intended for manual operation.
Caution
Before emergency manual operation is used, the door system must be safely disconnected
from the power supply. Emergency manual operation (HK) is only allowed with the motor
turned off, via hand crank, and can only be carried out by the service technician or instructed personnel. Emergency manual operation (LK) is also only allowed with the motor
turned off.
Attention
Emergency manual operation is not intended for long-term use (e.g., from commissioning
of the drive to continuous power supply).
Doors with counterweights must be set in such a way that they are fully counterweighted in
all positions. If the door is not counterweighted properly, the manual force required is increased and the service life of the emergency manual operation mechanism is reduced.
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(applies to cam-operated limit switching)
1.
2.
3
3.
4.
1.
2.
The door must not be moved beyond the limit positions as otherwise a safety limit switch
(S1F/S2F) is activated. If activated, electrical operation of the door system is only possible
when the safety limit switch (S1F/S2F) is “released” via emergency manual operation.
2 different systems are available for emergency manual operation:
• Crank handle (HK)
• Light chain (LK)
For each type of emergency manual override system, an appropriate notice (as per
EN60335-2-103) must be permanently placed in the vicinity of the corresponding operating element describing how it is to be used. Stickers for use as notices which are appropriate to the drive are included within the scope of delivery.
Crank handle (HK)
Operation
Remove the cover by turning it anticlockwise (1.) first, and then lifting it off (2.).
For emergency manual operation, the crank handle is inserted in the motor shaft.
The crank handle must firstly be snapped onto the motor shaft by applying slight
pressure (3.) and turning carefully (4.). Following this, proper emergency manual operation with the crank handle is possible.
The door can then be opened or closed with the crank handle by turning whilst applying slight pressure.
In order to prevent electrical operation of the door system during emergency manual
operation, the safety switch S3F is opened upon insertion of the crank handle.
Light chain (LK)
In the case of horizontal drive installation
Attention!Following operation, the crank handle must be completely removed
once more to allow electrical operation of the door system to resume. Once
the crank handle has been removed, the cover must be refitted in a clockwise
direction in order to maintain the drive's degree of protection. Make sure that
it clicks audibly into place.
Installation of the chain wheel
Mount the chain on the chain wheel so that there is roughly the same number of chain
links overhanging on both sides (1.). Then feed the two ends of the chain fully
between the deflection pulleys and the coupling shaft (2.).
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3.
4.
Light chain (LK)
1.
2.
3.
4.
In the case of vertical drive installation
Ensure that the centric mount on the chain wheel with the round hole and not the
hexagon is placed on the coupling shaft on the drive first (3.). Now secure the chain
wheel using a washer, spring washer and screw (4.). Tighten the screw (M8 – wrench
size 13) firmly whilst locking up the chain wheel (e.g. by holding both strands of the
chain).
The drive can be installed vertically at an installation height of up to approx.
8 m. From an installation height of approx. 8 m, the drive must be installed horizontally.
Installation of the chain wheel
Mount the chain on the chain wheel so that there are approx. 10 chain links overhanging on one side (1.). Then feed the two ends of the chain fully between the deflection rollers and the coupling shaft (2.).
Ensure that the centric mount on the chain wheel with the round hole and not the
hexagon is placed on the coupling shaft on the drive first (3.). Now secure the chain
wheel using a washer, spring washer and screw (4.). Tighten the screw (M8 – wrench
size 13) firmly whilst locking up the chain wheel (e.g. by holding both strands of the
chain).
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6.
7.
5.
Insertion of the chain ends
Take the short chain strand and align it so that the chain links are not twisted (5.).
Now insert the last link in the chain (6.) in the chain cross provided (7.) in accordance
with its alignment.
Pull the chain end which has just been inserted through the chain cross until approx.
10 chain links are protruding from the chain wheel at the other end of the chain.
Then proceed in the same way with the other side and also feed this end of the chain
through the chain cross in accordance with its alignment.
Light chain (LK)
Connection of the chain ends and operation
Connection of the chain ends
Before connecting the ends of the chain using the chain lock provided, it must be ensured that the chain is not twisted when it is mounted.
The chain lock must be fastened carefully.
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Operation
3~ 400 V
3~ 230 V
2
1
In order to prevent repeated coupling and decoupling of the emergency
manual operation mechanism, the chain must be kept taut during operation.
The door can be opened and closed manually by pulling the respective side of the
chain vertically. In order to prevent electrical operation of the door system during
emergency manual operation, the safety switch S3F is activated when the chain is
pulled. After operation, ensure that the chain hangs "freely" again so that the safety
switch SF3 is released and electrical operation is enabled once more. It may be necessary to pull briefly on the chain in order to release the safety switch.
Voltage switching
Caution
Before voltage switching, the drive must be safely disconnected from the mains.
The drives can be operated on a 3~ 400 V ( -star connection) or 3~ 230 V ( -delta connection) network. The drives are delivered
pre-wired for operation on a 3~ 400 V network.
For operation on a 3~ 230 V network, the drive must be switched from -star connection to -delta connection:
• Remove the “3 x 230 V” sticker (1)
• Switch the 6-phase motor plug (2) from to
Electrical connection to the control unit and connection diagram
Caution
The electrical connection may only be carried out by a qualified electrician! Please ensure
adherence to all data on the supplied control unit and all applicable EN standards! When all
connection work is being carried out, the door system must be safely disconnected from
the mains by removing the plug/switching off the main switch. Observe the drive’s technical data. The limits given in the technical data must not be exceeded. In particular, the
on-site fuse protection of the door system, to be carried out by the customer, must comply
with the technical data!
When laying the protective conductor, it must be ensured that the protective conductor
connection (earth) is disconnected last if the cable is pulled out unintentionally, e.g., by
bundling the individual black wires of the connecting cable together to form a loop and fixing this with a cable tie.
The individual wires must not be in contact with the gear wheels/cams of the limit switching
when the housing cover is closed.
Ensure that the connecting cable is routed in such a way that it is not in contact with the
drive.
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To connect the drive to the control unit, only use original manufacturer-approved 12-core or 18-core cables. The connecting cable
is plug-in. In order to ensure strain relief and the degree of protection, the gland must not be undone. The 10-pole jumper plug in
the drive must be removed before plugging in the 18-core cable. The plugs feature reverse polarity protection and click audibly
into place. The yellow/green protective conductor wire must be connected to the designated push-on connector . Make sure
that it engages firmly.
S1F -Safety limit switch OPEN - yellow
S2F -Safety limit switch CLOSE - yellow
S3F -Safety limit switch HK/LK
S4F -Thermoswitch
• Install the individual wires of the connecting cable to the right of the central dome
of the housing as shown in the diagram.
• Install the protective conductor (green/yellow) below the black connecting
cables.
• Secure the connecting cable to the internal motor cables using the supplied
cable tie.
S5 -Operational limit switch OPEN - grey
S6 -Operational limit switch CLOSE - black
S7 -Functional limit switch - orange
S8 -Functional limit switch - green
Checking the running direction
The direction of drive rotation depends on the mains connection to the control unit and must be checked first. Proceed as follows:
• Move the door into the semi-opened position using the emergency manual operation function.
• Insert the mains plug of the control unit into the socket or switch the main switch of the control unit on.
• Check that the control unit is in dead-man mode.
• Use the OPEN and CLOSE buttons to verify whether the running direction of the door corresponds to the buttons pressed.
If the running direction of the door does not correspond with the button commands, change the direction of rotation as described
in the Assembly and Operating Instructions for the control unit. Then check the running direction again.
Setting the door limit positions
The drive comes with 6 cam-operated end switches as standard. All cams have 12lock-in positions for quick adjustment. Check
that the control unit is in dead-man mode.
Proceed as follows to set the limit switch:
1. Turn all 6 cams out of the movement range of the door.
2. Use the DOWN button of the control unit to move the door to just before the lower limit position.
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3. Rotate the black cam S6 "CLOSE" on its shaft until the precision set screw is within easy reach. Now use the precision set
screw (slotted) to manually set the cam in such a way that it activates the switch. Move the door slightly up and down again until the end switch stops the door. Fine tune the setting as necessary.
4. Now move the door to just before the upper limit position.
5. Now set the grey cam S5 "OPEN" in the same way as described in point 3.
6. Now set the yellow safety cams S1F "UP" and S2F "DOWN" to lag both operational limit switches S5 "OPEN" and S6 "CLOSE".
7. The two functional cams S7 (orange) and S8 (green) can be set accordingly if required.
8. The limit switches are now set. Carry out a test run to check the set limit positions.
If the orange functional cam S7 is used as a pre-limit switch for functional switch-off of the
safety edge of the door, then it must switch a maximum of 5cm above the floor; EN12453
and EN12445.
Replace the housing cover on the limit switching system. Make sure that the seal and the lining groove are clean and that the cover
is properly positioned. Tighten the screws carefully.
Maintenance
Attention
The door system must be regularly checked by an expert to ensure that it is in safe working
order. The door manufacturer stipulates the frequency of maintenance and checks according to national regulations and the frequency of use.
Counterweight (applies to sectional doors with spring compensation or a counterweight):
The counterweight/spring tension must be checked. The sectional door should be counterweighted in every position. Note the
door's operating instructions.
The following checks must be performed on the drive:
1. Fastenings:
All fastening screws, including the screws to secure the torque bracket, must be checked to ensure they are in good condition and
fastened securely.
2nd Safety limit switches:
The functionality and switch-off point of the safety limit switches S1F, S2F and S3F must be checked. Follow the relevant assembly
and operating instructions for the door control unit. The safety limit switches must be checked for continuity as per the connection
diagram.
Re S1F / OPEN (applies to cam-operated limit switching)
Open to the upper limit position. Using the emergency manual operation function, keep opening up to the point where no damage
occurs. The safety switch S1F must be checked as per the connection diagram. There must be no continuity.
Re S2F / CLOSE (applies to cam-operated limit switching)
Close to the lower limit position. Using the emergency manual operation function continue closing until the load-bearing medium
(e. g., cables or chains) for suspending takes the complete weight of the door sections. It must be ensured that the cables do not
fall from the cable drum. The safety switch S2F must be checked as per the connection diagram. There must be no continuity.
Re S3F (applies to HK and LK drives)
Before inspecting the safety switch S3F, the door system must be disconnected from the mains.
Insert the crank handle (HK) in the motor shaft and turn through at least one revolution and hold the position or pull the light chain
(LK) and keep it taut.
The safety switch S3F must be checked as per the connection diagram. There must be no continuity.
3. Gears:
The gears are lubricated for life and maintenance-free.
4. Toothed belt
1. Check that the toothed belt (1) has sufficient preliminary tension.
2. Carry out a visual check of the toothed belt (1) along the complete travel distance of the door. The toothed belt (1) must show
no signs of wear.
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1
Technical data
Type Unit A100
Output torque T Nm 100
Output speed n min
Diameter of hollow shaft mm 25.4
Operating voltage U V 3~230 / 400
Frequency F Hz 50
Nominal current I A 4.6/2.6
Power factor Cos 0.64
*2)
Cycles
Insulation material class H
Thermoswitch °C 170
Degree of protection IP 54
Limit switch range Revolutions 13
Static holding torque Nm 450
On-site fuse protection 3x10AT
-1
25
1/h 6
Permissible ambient operating
°C -20 to +40
temperature
Emission sound pressure level dB(A) ≤ 70
*1)
Weight
*1)
) With the LK version, the weight increases by approx. 0.5 kg.
*2
) A cycle is an opening and closing over the entire limit switch range at the full output torque as specified in the technical data.
(approx.) kg 10
The actual door cycles depend on the design, e.g. size and weight of the door.
Deviations are possible in structurally identical drives or special drives.
The information on the type plate always applies.
Subject to technical changes without notice.
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Declaration of incorporation
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