BFT ICARO User Manual

AUTOMATION
FOR RACK
SLIDING GATES

ICARO

D811310 30-06-02 Vers. 03

99

Thank you for buying this product, our company is sure that you will be more
than satisfied with the product’s performance. The product is supplied with
a “Warnings” leaflet and an “Instruction booklet”. These should both be
read carefully as they provide important information about safety, installation,
operation and maintenance. This product complies with the recognised
technical standards and safety regulations. We declare that this product is
in conformity with the following European Directives: 89/336/EEC and 73/
23/EEC (and subsequent amendments).

1) GENERAL OUTLINE

The ICARO actuator offers ample installation versatility, thanks to the
extremely low position of the pinion, the compactness of the actuator and
to the height and depth which can be very easily adjusted. It is equipped
with an antisquash electronic device, which ensures utmost safety. The
emergency manual release can be activated very easily by means of a knob
featuring a personalised key.
The gate stop is controlled by electromechanical end-of-stroke microswitches
or, for very cold areas, by proximity sensors.
The control board can be built-in or installed onto a separate cabinet.

The gearmotor (fig. 1) is made up of the following:

M Motor
R Worm screw - worm wheel reduction gear
S Electromechanical end-of-stroke unit or proximity sensor
P Pinion with release
C Control board with capacitor
E Obstacle detection device (Encoder)

2) GENERAL SAFETY
WARNING! An incorrect installation or improper use of the product
can cause damage to persons, animals or things.

• The “Warnings” leaflet and “Instruction booklet” supplied with this
product should be read carefully as they provide important information
about safety, installation, use and maintenance.

• Scrap packing materials (plastic, cardboard, polystyrene etc) according
to the provisions set out by current standards. Keep nylon or polystyrene
bags out of children’s reach.

• Keep the instructions together with the technical brochure for future
reference.

• This product was exclusively designed and manufactured for the use
specified in the present documentation. Any other use not specified in
this documentation could damage the product and be dangerous.

• The Company declines all responsibility for any consequences resulting
from improper use of the product, or use which is different from that
expected and specified in the present documentation.

• Do not install the product in explosive atmosphere.

• The construction components of this product must comply with the

following European Directives: 89/336/CEE, 73/23/EEC, 98/37/EEC
and subsequent amendments. As for all non-EEC countries, the above­mentioned standards as well as the current national standards should
be respected in order to achieve a good safety level.

• The Company declines all responsibility for any consequences resulting
from failure to observe Good Technical Practice when constructing
closing structures (door, gates etc.), as well as from any deformation
which might occur during use.

• The installation must comply with the provisions set out by the following
European Directives: 89/336/CEE, 73/23/EEC, 98/37/EEC and
subsequent amendments.

• Disconnect the electrical power supply before carrying out any work on
the installation.

• Fit an omnipolar or magnetothermal switch on the mains power supply,
having a contact opening distance equal to or greater than 3mm.

• Check that a differential switch with a 0.03A threshold is fitted just before
the power supply mains.

• Check that earthing is carried out correctly: connect all metal parts for
closure (doors, gates etc.) and all system components provided with an
earth terminal.

• Fit all the safety devices (photocells, electric edges etc.) which are
needed to protect the area from any danger caused by squashing,
conveying and shearing.

• Position at least one luminous signal indication device (blinker) where
it can be easily seen, and fix a Warning sign to the structure.

• The Company declines all responsibility with respect to the automation
safety and correct operation when other manufacturers’ components
are used.

• Only use original parts for any maintenance or repair operation.

• Do not modify the automation components, unless explicitly authorised

by the company.

• Instruct the product user about the control systems provided and the
manual opening operation in case of emergency.

• Do not allow persons or children to remain in the automation operation
area.

• Keep radio control or other control devices out of children’s reach, in
order to avoid unintentional automation activation.

• The user must avoid any attempt to carry out work or repair on the
automation system, and always request the assistance of qualified
personnel.

• Anything which is not expressly provided for in the present instructions,
is not allowed.

3) TECHNICAL SPECIFICATIONS

Power supply: ..................................230V

±10% single-phase 50Hz (*)

Motor revolutions: ...................................................................... 1400 min

-1

Absorbed power: ............................................................................. 750 W

Capacitor: ................................................. 25 µF (230V) :100 µF (110V)

Thermal protection: .........................................................................140 °C

Insulation class: ........................................................................................F

Reduction gear ratio: .......................................................................... 1/38

Output revolutions: ........................................................................ 37 min

-1

Pinion pitch: .............................................................. 4 mm 18 or 25 teeth

Leaf speed: ............................... 9m/min (18 teeth).....:12m/min (25 teeth)

Max. capacity: .................................. with pinion Z18 20.000 N( ≈2000 kg)

with pinion Z25 10.000 N( ≈1000 kg)

Max. torque: ..................................................................................... 40 Nm

Impact reaction: ...............................Obstacle detection device (Encoder)

Lubrication: ................................................................................... ERGOIL

Manual manoeuvre: ........................................... Mechanical knob release

No. manoeuvres in 24 hours: .......................................continuous service

Control unit: ......................................................................................... LEO

Weather conditions: ................................................. from -15 °C to +60 °C

Protection degree: ............................................................................. IP 24

Dimensions: ..................................................................................See fig.2

Actuator weight: ................................................................................. 25 kg

(*) Special voltages on request

4) PRELIMINARY CHECKS

Before proceeding to any installation work, check that the gate structure
conforms to whatever is prescribed by the current standards, and in
particular that:

• The gate sliding track is linear and horizontal, and the wheels are

suitable for supporting the gate weight.

• The gate manual operation can be carried out smoothly along its entire

run, and there is no excessive side slipping.

• A correct play is provided between the upper guide and the gate to

ensure regular noiseless movement.

• The opening and closing gate stops are positioned.

• The established position for gearmotor fixing allows the emergency

manoeuvre to be carried out smoothly and safely. In the case where the
elements checked do not meet the above requirements, proceed to
carrying out the necessary corrective actions or replacements.

WARNING: Remember that control devices are intended to facilitate
gate operation, but can not solve problems due to any defects or
deficiency resulting from failure to carry out correct installation or
maintenance.

Take the product out of its packing and inspect it for damage. Should it be
damaged, contact your dealer. Remember to dispose of its components
(cardboard, polystyrene, nylon, etc.) according to the current prescriptions.

5) BASE PLATE ANCHORING

5.1) Standard position

• Dig a hole where the cement pad with the buried base plate log bolts is

to be placed in order to fix the reduction gear unit (fig.3). If the sliding
track is already there, digging must be partly carried out in the track
foundation casting. This way, should the track foundation casting sag,
the gearmotor base would also lower, thus maintaining the play between
pinion and rack (approximately 1-2 mm).

• Position the base plate according to the dimensions specified in fig.4.

• The pinion symbol printed on the base plate must be visible and directed

towards the gate. This also ensures the correct positioning of the
raceways for electrical connections.

• Let the flexible pipes containing electrical cables protrude from the

base plate.

• In order to keep the base plate in its correct position during installation,

it may be useful to weld two iron flat bars under the track, and then weld

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the log bolts onto them (fig.3).

• Make a concrete casting in such a way as to embody the base plate
casting into that of the gate track.

• Accurately check that:
The positioning dimensions are correct.
That the base plate is well levelled.
That the 4 stud threads are well clear of cement.
Let the casting harden.

5.2) Other positions

The gearmotor can be positioned in different ways. As an example, fig.5
illustrates a particular type of installation. In the case where the gearmotor
is not fixed on the level of the sliding track (Standard position), you must
ensure that the gearmotor is tightly secured also in relation to the gate
position, so as to maintain a correct play (1-2mm) between rack and
pinion. The current safety standards with respect to persons, animals and
things must be strictly observed, and in particular risks of accidents due to
squashing in the area of pinion-rack meshing, as well as other mechanical
risks, must be carefully avoided. All the critical spots must be protected

by safety devices in compliance with the current prescriptions.

6) GEARMOTOR FIXING

When the casting has hardened, observe fig. 6 and proceed as follows:

• Position an M10 nut on each of the tie rods, keeping a distance of at least
25mm from the base to allow the gearmotor to be lowered after the
installation is completed, or for subsequent adjustments of the play
between pinion and rack.

• Position a plate “P” supplied as standard on each pair of tie rods and, with
the help of a level, adjust the plane in both directions.

• Remove the cover and screw-cover guard from the gearmotor, and
position the reduction gear unit on the four tie rods with the pinion
facing the gate.

• Position the two upper plates P (Fig.6) and tighten the four locking nuts
of the gearmotor.

• Adjust the depth of the gearmotor, making it slide in the appropriate slots
found in the base, and fix it at a distance between pinion and gate which
is adequate to the type of rack to be installed. The rack teeth must mesh
into the pinion along their entire width. In the paragraph headed “Rack
fitting” we specify the measurements and installation methods of the
most widely used types of rack.

7) RACK FITTING

A rack having a 4 tooth pitch must be fitted to the gate. As far as the length
is concerned, this must include the passage space, as well as the space for
securing the brackets activating the limit microswitches, and for the pinion
meshing section. There are different types of rack, each one differing in
terms of capacity and gate fixing method. The Company markets three
types of racks, which are.

7.1) Mod. CFZ (Fig.7).

Galvanised iron rack - 22x22mm section - supplied in 2 - metre lengths ­capacity over 2000kg (≈ 20000N). First weld these pieces onto an adequate
iron angle bar and then weld the lot to the gate. Besides maintaining the
distance between the rack and the side of the gate, the angle bar makes it
easy to fix the rack to the gate, even when the latter is subject to slight side
slipping. When join welding the various rack pieces, you are advised to
arrange a section of rack as in (fig.8) to ensure a correct pitch along the
entire length of the rack.

7.2) Mod. CPZ (Fig.7).

Plastic rack - 22x22mm section - supplied in 1- metre lengths - max.
capacity 500kg (≈ 5000N). This model is to be fixed to the gate by means
of normal or self-threaeSng screws. Also in this case, you are advised to
insert a section of rack the other way round in the joint between the various
pieces, so as to maintain the correct tooth pitch. This type of rack is quieter
and allows height adjustments to be made even after having been fixed,
using the slots provided.

7.3) Mod. CVZ (Fig.7)

Galvanised iron rack - 30x12mm section - supplied in 1 - metre lengths ­threaded spacers to be welded - max. capacity 2000kg (≈ 20000N). Having
fixed the spacers in the middle of each of the slots in the various rack pieces,
weld the spacers to the gate. Also in this case, arrange a section of rack the
other way round in the joining points of the various rack pieces to ensure
a correct tooth pitch. The screws which fix the rack to the spacers allow the
rack to be adjusted in height.

7.4) Rack fitting

To fit the rack, proceed as follows:

• Activate the emergency release by rotating the appropriate release
knob (See paragraph “Emergency manoeuvre”).

• Rest the rack end on the control pinion and secure it (by welding or using
screws) in correspondence with the pinion, while sliding the gate along
by hand (fig. 9).

• In the case of incorrect gate alignment (excessive side curving) which
cannot be corrected, place a few shims between the rack and gate in
order to ensure continuous centring of the rack with respect to the pinion
(fig. 10).

DANGER - The welding operation is to be carried out by a competent
person who must be provided with all the personal protection
equipment required by the current safety standards.

8) PINION ADJUSTMENT

Having finished fixing the rack, the rack-pinion play needs to be adjusted
to approximately 2mm (fig.6): this is obtained by slackening the four M10
nuts under the gearmotor base by approximately 2mm, and then securing
the four upper nuts. Make sure that the rack and pinion are aligned and
centred (fig.10).

WARNING - Remember that the rack and pinion life strictly depends
on their correct meshing.

9) ELECTROMECHANICAL LIMITING DEVICES

The operation must be carried out with the emergency release activated
and the mains power supply disconnected. The runners which control the
limiting devices are to be positioned at both ends of the rack.

- Push the gate fully open by hand.

- Position the opening end-of-stroke runner (fig.11) so that it intercepts the

microswitch control lever and makes it trigger. Having identified the
correct position, tighten the runner screws.

- Push the gate fully closed by hand.

- Position the closing end-of-stroke runner (fig.11) so that it intercepts the

microswitch control lever and makes it trigger. Having identified the
correct position, tighten the runner screws.

- The runners must lock the gate before this intercepts the mechanical
backstops placed on the track. The closing end-of-stroke runner
adjustment must be made in such a way as to leave a clearance of
approximately 50mm between the gate and the fixed swing leaf, as
prescribed by the current safety standards, otherwise fit an electric edge
at least 50mm thick (fig.12).

10) GATE BACKSTOPS

DANGER - The gate must be provided with mechanical backstops,
both on opening and closing, in order prevent it from coming out of
the upper guide (fig.13); the backstops must be tightly secured to the
ground, a few centimetres beyond the electrical stop point.

11) ELECTRICAL INSTALLATION SETUP

Lay out the electrical installation as shown in fig.15 with reference to the CEI
64-8 and IEC364 provisions complying with the HD384 and other national
standards in force for electrical installation.

WARNING! For connection to the mains, use a multipolar cable
having a minimum cross section of 3x1.5 mm

2

and complying with the
current standards. (For example, if the cable is not protected, it must
be at least equal to H07 RN-F, whereas if it is protected it must be at

Connect the control and safety devices in compliance with the previously
mentioned technical installation standards.
The cables (mains and auxiliary) must be distinctly separated in their cable
clamp (P1-P2/Fig.16).
Fig.15 shows the number of connections and their cross sections for a
length of approximately 100 metres; for greater lengths, calculate the cross
section for the true automation load.

The main automation components are (fig.15):
I Type-approved adequately rated omnipolar circuit-breaker with

at least 3-mm contact opening, provided with protection against
overloads and short circuits, suitable for cutting out automation
from the mains. If not already installed, place a type-approved
omnipolar circuit-breaker with a 0.03A threshold just before the
automation system.

QR Control panel and incorporated receiver.
S Key selector.
AL Blinker with tuned antenna.
M Actuator
P Wall-mounted pushbutton panel.
Fte, Fre Pair of external photocells.
T 1-2-4 channel transmitter.

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12) TERMINAL BOARD CONNECTIONS

First pass the appropriate electric cables through the raceways and fix the
various automation components to the chosen points, then connect them
following the directions and diagrams contained in the control unit instruction
manual.
Carry out phase, neutral and (compulsory) earth connections. The protection
wire (earth) with yellow/green insulating sheath must be connected to the
appropriate terminals marked by their symbol.
Operate the automation only after having connected and checked all the
safety devices.

The mains power supply cables must be stripped as little as possible; the
power supply cable earth wire must be stripped for a greater length, in order
to reach the terminal purposely arranged in the box (fig. 16 ref. “A”).
The P1 cable-clamp is reserved for the mains power supply cables, the P2
cable-clamp is reserved for the accessory cables and safety devices.
The cables must be tied by additional fastening next to the terminals, by
means of clips for example.
All the operator wiring operations must be carried out by qualified personnel.

A description of the terminals in the control board mod. LEO mounted on the
actuator (fig.14) is provided here below:

JP1

1

GND terminal

2-3 Single-phase mains supply 230V

±10% 50Hz (2=N) (3=L)

JP2

4-5 Blinker connection (mains voltage) 40W Max.
6-7-8-9 Motor connection:

6 operation 1 (brown) + capacitor
7 common (blue)
8 operation 2 (black)
9 capacitor

JP3

10-11 Output 24V 180mA max – power supply for photocells or

other devices.

12-13 Gate-open warning light output (24V 3W max)

JP5 Encoder connection

WARNING! The maximum length of the connection cable of

the encoder should not exceed 3.00 m.

JP6

21-22 Open-Close button (N.O. Start), key selector.
21-23 Block button (N.C. Stop). If not used, leave jumped.
21-24 Photocell input (N.C.). If not used, leave jumped.
21-25 Opening limit switch connection (N.C. SWO). If not used,

leave jumped.

21-26 Closing limit switch connection (N.C. SWC). If not used, leave

jumped.
21-27 Pedestrian button connection (N.O. Ped)
21-28 Open-Button connection (N.O. Open)
21-29 Close-Button connection (N.O. Close)
21-30 Rubber edge connection (N.C.). If not used, leave jumped.
21-31 Timer input connection (N.O.). If the contact is open the leaves

close and the gate is ready for normal operation. If the contact

is closed (N.C.), the leaves open and remain open until the

contact is opened. If not used, leave jumped.

JP9

34 TX1 serial output
35 TX2 serial output
36 RX1 serial imput
37 RX2 serial input
38-39 Antenna input for snap-in radio receiver board (38 signal - 39

braid). Cable RG58
40-41 Second radio channel output of twin-channel receiver board

WARNING - If the opening direction is not correct, invert the motor
connections no. 6 and 8 and connections no. 25 and 26 of the opening and
closing limit switches.

13) MOTOR TORQUE SETTING

WARNING: Check that the impact force value measured at the
points established by the EN 12445 standard is lower than that
specified in the EN 12453 standard.

The setting of the motor torque is electronically controlled by an encoder.
Refer to the LEO control board instructions for a correct setting of the
electronic antisquash safety device.

WARNING! The ICARO actuator does not offer the possibility of
adjusting the safety clutch. It is therefore necessary to use a
control board prearranged for the electronic control of the
motor torque.

14) MANUAL RELEASE

The manual or emergency release should only be activated when the gate
has to be opened manually or whenever the automation is not correctly or
totally functioning.
To carry out the emergency manoeuvre, proceed as follows:

• Insert the personalised key into the lock and turn it anticlockwise by 90°.

• Turn the release knob clockwise (fig. 17) as far as it will go. The pinion

will therefore become idle and the gate can then be opened manually.

• Push the leaf of the gate all the way down to the end-of-stroke.
Warning: do not push the gate leaf roughly, but move it gently all along
its stroke.
The key can be removed from the lock only after the knob has been
moved back to its initial position (motor-driven operation)

• To re-activate motor-driven control, turn the knob anticlockwise as far as
it will go. Move the key back to its closing position, remove it and then
store it in a safe place, which is known to anyone who may need the
knob.

15) INSTALLATION CHECK

Before the automation device finally becomes operational, scrupulously
check the following conditions:

• Check that all the safety devices (limit microswitches, photocells, elec-

tric edges etc) operate correctly.

• Check that the rack and pinion are correctly meshed (minimum play 2mm).

• Check that the pushing force of the gate is within the limits provided for

by the current standards.

• Check that the opening and closing end-of-stroke runners are correctly

positioned and tightly secured.

• Check the starting and stopping operations using the manual control.

• Check the starting and stopping operations using the remote radio control.

• Check the normal or customised operation logic.

16) AUTOMATION DEVICE USE

Since the automation device can be controlled both remotely and in sight,
by means of a radio control device or a button, all the safety devices must
be frequently checked in order to ensure their perfect efficiency.

WARNING! In the event of any safety device malfunction, request
immediate assistance from qualified personnel.Children must be kept
at a safe distance from the automation operation area.

17) AUTOMATION CONTROL

The use of this control device allows the gate to be opened and closed
automatically. There are different types of controls (manual, radio control,
magnetic card access etc.) depending on the installation requirements and
characteristics. For the various control systems, see the relevant instruc­tions.

The installer undertakes to instruct the user about correct automa­tion operation, also pointing out the actions to be taken in case of
emergency.

18) MAINTENANCE

WARNING! Before proceeding to any maintenance, disconnect the
mains power supply and, if the battery is fitted, one of its poles.

These are the check and maintenance operations to be carried out:

• Check the condition of lubrication of the metal racks once a year.

• Keep the sliding track always clean and free from debris.

• Occasionally clean the photocell optical elements.

• Have a qualified technician (installer) check the correct torque limit

setting.

• When any operational malfunction if found, and not resolved, disconnect
the mains power supply and request the assistance of a qualified
technician (installer). When the automation controller is out of service,
you can activate the manual release device (see paragraph on
“Emergency manoeuvre”) in order to set the pinion idling and therefore
allow the gate to be opened and closed by hand.

19) NOISE

The environmental noise produced by the gear-motor in normal operation
conditions is constant and does not exceed 70 dB (A).

20) SCRAPPING

Materials must be disposed of in conformity with the current regula­tions.

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In case of scrapping, the automation devices do not entail any particular risks
or danger. In case of materials to be recycled, these should be sorted out by
type (electrical components, batteries, copper, aluminium, plastic etc.).

21) DISMANTLING

When the automation system is disassembled to be reassembled on
another site, proceed as follows:

• Disconnect the power supply and the entire electrical installation.

• Remove the gearmotor from its fixing base.

• Disassemble the control panel, if separate, and all installation

components.

• In the case where some of the components cannot be removed or are
damaged, they must be replaced.

22) MALFUNCTIONS AND REMEDIES

22.1) Faulty actuator operation

• Use an appropriate instrument to check that the actuator ends are

supplied with voltage after the opening or closing command.

• If the leaf movement is opposite to that required, reverse the motor drive

connections in the control unit.

22.2) Faulty operation of electrical accessories

In case of fault, all the control and safety devices can cause the automation
controller to malfunction or lock. If the control unit is provided with self­diagnosing facility, identify the fault. If a fault is found, it is advisable to
disconnect and, if necessary, bridge, all the automation control devices one
by one, until the one causing the fault is identified. Replace or repair it, then
reset all the devices which were previously disconnected or bridged. For all
the devices installed, make reference to the respective instruction manual.

WARNING! Correct controller operation is only ensured when the data
contained in the present manual are observed. The company is not to
be held responsible for any damage resulting from failure to observe
the standards relating to safety, installation and good technical
practice, as well as the instructions contained in the present manual.

The descriptions and illustrations contained in the present manual
are not binding. The Company reserves the right to make any altera­tions deemed appropriate for the technical, manufacturing and com­mercial improvement of the product, while leaving the essential
product features unchanged, at any time and without undertaking to
update the present publication.

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Fig. 1

Fig. 2

Fig. 4Fig. 3

260

10.75

168

217

10.75

16 16

226

21.521.5

3535 55

260

Min. 127 mm (Z18)

Min. 141 mm (Z25)

20

Min. 94w mm

AXI PIGNON - RITZELACHSE - CENTRO PINON

CENTRO PIGNONE - PIGNON CENTER

160

100

260

376

152

65

22

40

Z25 ¯p100

Z18 ¯p72

C

E

M

P

P

C

S

M

R

R 20

90

226

R 20

56.531.5

270

2222

212.557.5

40

10760

11

178

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Fig. 6

Fig. 8

Fig. 10

Fig. 7

Fig. 9

Fig. 5

20

1-2mm

65>29

10

P

CFZ CPZ CVZ

37

30

12

20

30

32

28

22

22

P

NO

OK

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Fig. 13 Fig. 14

Fig. 15

C

QR

3x1mm

2

T

3x1.5mm

2

2x1.5mm

2

3x1.5mm

2

RG58

AL

M

I

P

S

3x1.5mm

2

3x1.5mm

2

Fre

Fte

4x1mm

2

2x1.5mm

2

LEO

JP1

JP2

1

2

3

C

4

5

6

7

8

9

21

22

23

24

25

26

27

28

29

30

31

L

N

GND

JP8

START

COM

NO

NC

NC

NO

NC

NO

NO

NO

NC

NO

STOP

M

ANT.

SWC

PED

OPEN

CLOSE

TIMER

COSTA

II¡CH.R

24 V~

PHOT

SW0

10

11

12

13

JP3

ANT

SHIELD

24 V~

40W max.

34

35

36

37

38

39

40

41

JP9

24V

3W max.

SCA

TX1

RX1

RX2

TX2

Fig. 11

Fig. 12

DXSX

Min. 50mm

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Fig. 17

1

2

OPEN

CLOSE

Fig. 16

P1

A

GND

P2

A

LEO

JP1

2N

3L

1 GND

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