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ICARO
User Manual
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BFT ICARO User Manual

AUTOMATION FOR RACK SLIDING GATES
ICARO
D811310 30-06-02 Vers. 03
99
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
ICARO
ICARO
AUTOMATION FOR RACK SLIDING GATES
AUTOMATION FOR RACK SLIDING GATES
D811310_03
100
D811310_03
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.
ICARO
ICARO
AUTOMATION FOR RACK SLIDING GATES
AUTOMATION FOR RACK SLIDING GATES
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