FAAC 780D User Manual

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EC DECLARATION OF CONFORMITY FOR MACHINES

(DIRECTIVE 98/37/EC)

Manufacturer: FAAC S.p.A.

Address: Via Benini, 1 - 40069 Zola Predosa BOLOGNA - ITALY

Declares that: Operator mod. 746ER with electronic control unit 780D

• is built to be integrated into a machine or to be assembled with other machinery to create a machine under the provisions
of Directive 98/37/EC;

• conforms to the essential safety requirements of the following EEC directives:

73/23/EEC and subsequent amendment 93/68/EEC.
89/336/EEC and subsequent amendment 92/31/EEC and 93/68/EEC

and also declares that it is prohibited to put into service the machinery until the machine in which it will be integrated or
of which it will become a component has been identified and declared as conforming to the conditions of Directive 98/
37/EC.

Bologna, 01 January 2004

The Managing Director

A. Bassi

WARNINGS FOR THE INSTALLER

GENERAL SAFETY OBLIGATIONS

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)

Carefully read the instructions before beginning to install the product.

3) Do not leave packing materials (plastic, polystyrene, etc.) within reach
of children as such materials are potential sources of danger.

4) Store these instructions for future reference.

5) This product was designed and built strictly for the use indicated in this
documentation. Any other use, not expressly indicated here, could
compromise the good condition/operation of the product and/or be a
source of danger.

6) FAAC declines all liability caused by improper use or use other than that
for which the automated system was intended.

7) Do not install the equipment in an explosive atmosphere: the presence
of inflammable gas or fumes is a serious danger to safety.

8) The mechanical parts must conform to the provisions of Standards EN
12604 and EN 12605.
For non-EU countries, to obtain an adequate level of safety, the Standards
mentioned above must be observed, in addition to national legal
regulations.

9) FAAC is not responsible for failure to observe Good Technique in the
construction of the closing elements to be motorised, or for any
deformation that may occur during use.

10) The installation must conform to Standards EN 12453 and EN 12445.
For non-EU countries, to obtain an adequate level of safety, the Standards
mentioned above must be observed, in addition to national legal
regulations.

11) Before attempting any job on the system, cut out electrical power .

12) The mains power supply of the automated system must be fitted with an
all-pole switch with contact opening distance of 3mm or greater. Use
of a 6A thermal breaker with all-pole circuit break is recommended.

13) Make sure that a differential switch with threshold of 0.03 A is fitted
upstream of the system.

14) Make sure that the earthing system is perfectly constructed, and
connect metal parts of the means of the closure to it.

15) The automated system is supplied with an intrinsic anti-crushing safety
device consisting of a torque control. Nevertheless, its tripping
threshold must be checked as specified in the Standards indicated at
point 10.

16) The safety devices (EN 12978 standard) protect any danger areas
against mechanical movement Risks, such as crushing, dragging,
and shearing.

17) Use of at least one indicator-light (e.g. FAACLIGHT ) is recommended
for every system, as well as a warning sign adequately secured to the
frame structure, in addition to the devices mentioned at point “16”.

18) FAAC declines all liability as concerns safety and efficient operation
of the automated system, if system components not produced by
FAAC are used.

19) For maintenance, strictly use original parts by FAAC.

20) Do not in any way modify the components of the automated system.

21) The installer shall supply all information concerning manual operation
of the system in case of an emergency, and shall hand over to the
user the warnings handbook supplied with the product.

22) Do not allow children or adults to stay near the product while it is
operating.

23) Keep remote controls or other pulse generators away from children,
to prevent the automated system from being activated involuntarily.

24)

Transit is permitted only when the automated system is idle.

25) The user must not attempt any kind of repair or direct action whatever
and contact qualified personnel only.

26) Maintenance: check at least every 6 months the efficiency of the
system, particularly the efficiency of the safety devices (including,
where foreseen, the operator thrust force) and of the release devices.

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

18

%

%

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%

AUTOMATED SYSTEM 746 & ELECTRONIC CONTROL UNIT 780D

These instructions apply to the following models:

746 ER Z16 - 746 ER Z20 - 746 ER CAT - 746 ER RF

The FAAC mod. 746 automated system for sliding gates is an
electro-mechanical operator transmitting motion to the sliding leaf
via a rack or chain pinion appropriately coupled to the gate.
The non-reversing system ensures the gate is mechanically locked
when the motor is not operating and, therefore, no lock needs to be
installed.
The gearmotor is equipped with a mechanical clutch which,
combined with an electronic device, offers the necessary adjustable
anti-crushing safety and guarantees stopping or reversing the gate
movement. A handy manual release makes it possible to move the
gate in the event of a power cut or malfunction. The electronic
control equipment is equipped with a gearmotor and is housed
inside the operator.

The 746 automated system was designed and manufactured to
control access of vehicles. Avoid any other use whatever.

















where:
Ta = opening time
Tc = closing time
Tp = pause time
Ti = time of interval between two complete cycles

Use frequency graph

Duty

% Freq.

Cycl e

Utilizzo

100

90

80

70

60

50

40

30

20

10

0

Tempo (h) Time (h)

% Fréq .
d’uti li sation

123456789101112

Benutzun gs-

frequenz

Temps (h) Zeit (h) Tiempo (h) werkt ijd (h)

% Frecuenci a
de util ización

gebrui ks

frequent ie





 Securing corners
 Pinion
 Limit sensor switch
 Operator cover
 780 D Control board



 Oil filling plug
 Operator earthing
 Lever operated release system
 Protective side panels
 Cover for 780D control board

 Adjustment screw for

anti-crushing clutch

Fig. 1

1. DESCRIPTION AND TECHNICAL SPECIFICATIONS

1.1. MAXIMUM USE CURVE

The curve makes it possible to establish maximum work time (T)
according to use frequency (F).
E.g.: The 746 gearmotor can operate non-stop at 70% use
frequency.

To ensure efficient operation, operate in the work range below the
curve.
Important: The curve is obtained at a temperature of 24°C. Exposure
to the direct sun rays can reduce use frequency down to 20%.

Calculation of use frequency

The percentage of effective work time (opening + closing) compared
to total time of cycle (opening + closing + pause times).

Calculation formula:

%F =

Ta + Tc

X 100

Ta + Tc + Tp + Ti

Tab. 1 TECHNICAL SPECIFICATIONS OF 746 GEARMOTOR

MODEL 746
Power supply (Vac +6% -10% 50-60Hz) 230
Absorbed power (W) 300
Reduction ratio 1 : 30
Type of pinion Z20 - Z16
Rack Module 4 - step 12.566
Max. thrust (daN) 50 (Z20) - 62,5 (Z16)
Max. Torque (Nm) 20
Winding thermal protection (°C) 120
Use frequency 70% (see graph)
Oil quantity (l) 1,8
Type of oil FAAC XD 220
Operatine ambient temperature (°C) -20 ÷ +55
Gearmotor weight (Kg) 14
Protection class IP 44
Gate max. weight (Kg) 400 (Z20) - 600 (Z16)
Gate speed (m/min) 12 (Z20) - 9,6 (Z16)
Gate max. length (m) (time-out) 50 (Z20) - 40 (Z16)
Clutch twin-disk in oil bath
Protective treatment cataphoresis
Equipment 780D
Limit-switch MSL or inductive
Gearmotor overall dimensions LxHxD (mm) see Fig. 2

Electric motor technical specifications
RPM 1400
Power (W) 300
Absorbed current (A) 1.5
Starting capacitor (µF) 25
Power supply (Vac +6% -10%; 50-60Hz) 230

19

2. DIMENSIONS

3. ELECTRIC EQUIPMENT (standard system)

To make the connections efficiently, allow the cables to
project by about 40 cm from the hole (Figs.5-6 ref.) of the
foundation plate.

Fig. 4

Fig. 2

 Operator 746

with 780D equipment

 Photocells
 Key-operated push-button
 Flashing lamp
 Radio receiver

Fig. 3

4. INSTALLATION OF THE AUTOMATED SYSTEM

4. 1. PRELIMINARY CHECKS

To ensure safety and an efficiently operating automated system,
make sure the following conditions are observed:

• The gate structure must be suitable for automation. The following
are necessary in particular: wheel diameter must be in proportion
to the weight of the gate to be automated, an upper guide must
be provided, plus mechanical stop limits to prevent the gate
derailing.

• The soil must permit sufficient stability for the foundation plinth.

• There must be no pipes or electric cables in the plinth excavation
area.

• If the gearmotor is exposed to passing vehicles, install, if possible,
adequate means of protection against accidental impact.

• Check if an efficient earthing is available for connection to the
gearmotor.





Fig. 5

Fig. 6

Fig. 7

4.2. MASONRY FOR FOUNDATION PLATE

1) Assemble the foundation plate as shown in figure 4.

2) The foundation plate must be located as shown in figure 5 (right
closing) or figure 6 (left closing) to ensure the rack and pinion
mesh correctly.

3) Prepare a foundation plinth as shown in fig.7 and wall the
foundation plate, supplying one or more sheaths for routing
electric cables. Using a spirit level, check if the plate is perfectly
level. Wait for the cement to set.

4) Lay the electric cables for connection to the accessories and
power supply as shown in figure 3.

4. 3. MECHANICAL INSTALLATION

1) Assemble the securing corners and anti-vibration spacers on
the operator as shown in Fig. 8.

2) Open the cover, unscrewing the securing screws.

3) Place the operator on the plate, using the supplied washers and
nuts as shown in Fig. 9.
During this operation, route the cables through the duct inside
the lower half-casing of the operator (Fig.10 - Ref. A).
To access the electronic equipment, route the cables through
the appropriate hole, using the supplied rubber cable-clamp.
Make absolutely sure to unsheathe all the cables so that the
clamp holds single cables only (Fig.10 - Ref. B).

20

5) Secure the gearmotor to the foundation plate, tightening the
nuts as in Fig.12.

6) Prepare the operator for manual operating mode as described
in chapter 8.

Fig. 12

Fig. 8

Fig. 9

AB

Fig. 10

4. 4. INSTALLING THE RACK

4.4.1. STEEL RACK TO WELD (Fig.13)

1) Place the three threaded pawls on the
rack element, positioning them at the
top of the slot. In this way, the slot play
will enable any adjustments to be
made.

2) Manually take the leaf into its closing
position.

3)

Lay the first piece of rack level on the
pinion and weld the threaded pawl
on the gate as shown in figure15.

4) Move the gate manually, checking if the rack is resting on the
pinion, and weld the second and third pawl.

5) Bring another rack element near to the previous one, using a
piece of rack (as shown in figure 16) to synchronise the teeth of
the two elements.

6) Move the gate manually and weld the three threaded pawls,
thus proceeding until the gate is fully covered.

Fig. 13

4.4.2. STEEL RACK TO SCREW (Fig. 14)

1) Manually take the leaf into its closing position.

2) Lay the first piece of rack level on
the pinion and place the spacer
between the rack and the gate,
positioning it at the top of the slot.

3) Mark the drilling point on the gate.
Drill a Ø 6,5 mm hole and apply
thread with a Ø 8 mm male tap.
Screw the bolt.

4) Move the gate manually, checking
if the rack is resting on the pinion,
and repeat the operations at point

3.

5) Bring another rack element near to the previous one, using a
piece of rack (as shown in figure 16) to synchronise the teeth of
the two elements.

6) Move the gate manually and carry out the securing operations
as for the first element, thus proceeding until the gate is fully
covered.

Fig. 14

Fig. 11

4.4.3. NYLON RACK TO SCREW (Fig.14bis)

1) Manually take the leaf into its
closing position.

2) Lay the first piece of the rack level on
the pinion and mark the drilling point
on the gate; drill Ø 4 mm and screw
the self-tapping screw 6 x 20 mm to
the relevant reinforcing plate.

3) Move the gate manually, checking
if the rack is resting on the pinion,
and repeat the operations at point

2.

4) Bring another rack element near to the previous one, using
a piece of rack (as shown in figure 16) to synchronise the
teeth of the two elements.

5) Move the gate manually and carry out the securing
operations as for the first element, thus proceeding until the
gate is fully covered.

Fig. 14bis

21

Fig. 19

Fig. 15

Fig. 16

Notes on rack installation

• Make sure that, during the gate travel, all the rack elements do
not exit the pinion.

• Do not, on any account, weld the rack elements either to the
spacers or to each other.

• When the rack has been installed, to ensure it meshes
correctly with the pinion, we advise
you to lower the gearmotor position
by about 1.5 mm (Fig.17).

• Manually check if the gate
habitually reaches the mechanical
stop limits and make sure there is no
friction during gate travel.

• Do not use grease or other lubricants
between rack and pinion.

Fig. 17

4.5.2. MOD. 746 ER RF (Figs. 20 - 21)

1) Insert the spring pin  on the shaft, using a hammer.

2) Fit the idle transmissions bracket on the gearmotor flange,
using the four screws  (M5 x 12) and the appropriate
washers , in the kit as shown in Fig. 20.

3) Fit the chain pinion on the shaft, making the pinion seats
coincide with the spring pin and tighten the screw  and
the appropriate washers  and .

4) Pass the chain as shown in Fig. 21 ref. A and install the
housing with screw  and washer  as in Fig. 20.

5) In case of operators with MLS limit switches, arrange the
supports for the positioning of the magnets supplied while
observing the dimensions given in fig. 21 ref. B.

















Fig. 20

4.5. INSTALLATION OF CHAIN PINIONS

In the versions for applications with chain and idle transmissions,
a Z16 or Z20 chain pinion must be installed. Proceed as follows:

4.5.1. MOD. 746 ER CAT (Figs. 18 - 19)

1) Insert the spring pin on the shaft, using a hammer.

2) Fit the chain pinion on the shaft, making the pinion seats
coincide with the spring pin and tighten the screw with the
appropriate washers.

Fig. 18

A

5÷12 mm

0÷10 mm

B

Fig. 21

22