INSTALLATION MANUAL
GB
®
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
SCREW SEAT FOR FIXING THE
COVER/UPPER SECTION
OIL CONTAINER
ELECTRIC MOTOR
TOP END CAP
FADINI OIL
A 15 BY AGIP
HYDRAULIC LOBE PUMP
TWO-WAY
LOCKING VALVE
“B”
230 V-25 W LAMP
ELECTRIC TERMINAL COVER
ELECTRIC TERMINALS
“S”
AIR BLEED SCREW
O.33 HP ELECTRIC MOTOR
OIL RESERVOIR
FADINI OIL A 15 BY AGIP
MANUAL RELEASE LEVER
PRESSURE VALVE
ASSEMBLY
PISTON SLEEVE
GEAR BOX
HOUSING
TOOTHED SHAFT
SPACER BEARING/
GEAR TEETH
COVER
SCREW SEAT FOR FIXING
THE COVER/BOTTOM END
“C”–“A”
TWO-WAY LOCKING
VALVE ASSEMBLY
FADINI OIL A 15 BY AGIP
st
1
PISTON WITH STEEL INSERT
SHAFT SUPPORT
nd
PISTON WITH STEEL INSERT
2
FADINI OIL A 15 BY AGIP
RACK
PIC. 1
2
BOTTOM SECTION
CYLINDER END CAP
INSTRUCTIONS FOR THE INSTALLATION OF APROLI 480 TO A GARAGE DOOR WITH COUNTERWEIGHTS
PIC. 2
WEATHER STRIP
WALL FRAME
DOOR JAMB
COUNTERWEIGHT WHEEL
GUIDE ARM
TELESCOPIC ARM
COUNTERWEIGHT
COUNTERWEIGHT CASE
BOTTOM DOOR WHEEL
100x5 mm REINFORCEMENT
PLATE TO BE FIXED TO
THE DOOR FRAME
DOOR HANDLE
DOOR
UPPER EDGE
GARAGE DOOR
LATERAL SUPPORT
WEATHER STRIP
APROLI 480
WITH COVER
WEATHER STRIP
FIXING BRACKET
“M”
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
TRANSMISSION BAR
WITH SHAFT FITTING
SLEEVE (SQUARE
HOLE) WELDED TO IT
TRANSMISSION BAR
LATERAL SUPPORT
AIR BLEED
MAX. PRESSURE SAFETY VALVE
OPEN. RED
“S”
TELESCOPIC
ARM
“A”
“M”
FIXING
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
WALL FRAME
DOOR
FRAME
DOOR
FIXING
2˙500
“M”
DOOR JAMB
GUIDE ARM OF THE
EXISTING DOOR
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
60
80
TELESCOPIC ARM TO BE
PARALLEL FIXED TO THE
EXISTING DOOR ARM
20
FIXING PLATE
TO WELD
90
60
REINFORCEMENT
OPEN
APROLI 480
CLOSED DOOR
POSITION
100 x 5
DOOR JAMB/
COUNTERWEIGHT
CASE
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
EXISTING
GUIDE ARM
40
40
5°
FIXING
ABOVE
THE ARM
PIVOT
TELESCOPIC ARM OVERLAPPING THE DOOR ARM WHEN
THERE IS NO SPACE BETWEEN ARM AND COUNTERWEIGHT
FIXING ON TO THE
GUIDE ARM
OPERATOR IN THE
OPEN POSITION
10
FIXING ON TO
THE GUIDE ARM
BRACKET
40
“M”
TELESCOPIC ARM
OVERLAPPING THE
DOOR ARM WHEN
THERE IS NO SPACE
BETWEEN ARM AND
COUNTERWEIGHT
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. 7PIC. 5
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
FIXING PLATE
CLOSED DOOR
TELESCOPIC
ARM
LEVEL LEVEL
LATERAL
SUPPORT
TORSION BAR
“B”
LATERAL SUPPORT
PROVIDED WITH
THE EQUIPMENT
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.
TELESCOPIC ARM
WITH SLIDING BAR
CUT TO MEASURE
AND WELD
CIRCULAR WELDING
FIXING PLATE
TELESCOPIC ARM
WITH SLIDING BAR
CUT TO MEASURE
AND WELD
LEVEL LEVEL
LATERAL SUPPORT
TORSION BAR
WITH SLEEVE
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
IN THIS POSITION THE DOOR
MUST BE WELL BALANCED.
SHOULD IT NOT, ADD SOME
EXTRA COUNTERWEIGHT
FIX THE COVER
ONLY AFTER
COMPLETING THE
INSTALLATION
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.
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 “OPEN”
RED IN COLOUR
MAXIMUM
PRESSURE VALVE
“CLOSE”
GREEN COLOUR
“A”
“C”
“S”
“B”
AIR BLEED
RELEASE LEVER
TURN IT
ANTI-CLOCKWISE
MORE
POWER
PIC. 11
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.
7
RELEASE
LEVER
“B”
RUBBER STOP
OPEN
RUBBER STOP
25
RUBBER STOP ON
THE OUTSIDE OF THE DOOR
RECOMMENDED STARTING POSITION
BEFORE CLOSE CYCLE
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.
CLAMP
RELEASE
LEVER
“B”
LOCKABLE
HATCH DOOR
RELEASE CORD
PIC. 13
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
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».
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
EXTRA CAPACITOR IN CASE OF
POWER SHORTAGE OR TO IMPROVE
THE POWER OF THE OPERATOR
WHEN HEAVY DOORS ARE INVOLVED
PIC. 14
COURTESY
LIGHT
TO REVERSE THE DIRECTION OF THE
SHAFT ROTATION SWOP WIRES ROUND
No. 10 AND No. 12 DO NOT CHANGE No.11
10 11 12 13 14
ELPRO 6 exp
PIC. 15
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
98
ELECTRICAL WIRING DIAGRAM OF THE OIL-HYDRAULIC GARAGE DOOR OPERATOR
open
APROLI 480 TO THE ELECTRONIC CONTROL PANEL
BIRIO A8 AERIAL
TRANSFORMER
ASTRO 43
PLUG-IN
RADIO CONTROL
PLUG-IN CARD SUPPORT
ASTRO 43/2 RADIO RECEIVER
PLUG-IN PC BOARD
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.
LED ON VOLTAGE
24 V OUTPUT
1° CHANNEL
DIP-SWITCH
ON
12
- COURTESY LIGHT FOR TWO MINUTES. ON - FLASHING LAMP. OFF
- AUTOMATIC RE-CLOSING. ON - SEMI-AUTOMATIC.OFF
OFF
MOTOR RUN
OPEN & CLOSE TIME
DWELL TIME
SUPPLIED
CAPACITOR
024
meth
8VA
12,5 µF
230 0
FUSE
630 mA
FUSES
5 A
BUTTON ON
THE COVER LID
1234 56789
24 V OUTPUT A.C.
LIMIT SWITCH. OPEN. N.C.
LIMIT SWITCH. COMMON
N.O. CONTACT. OPEN SWITCH
STOP CLOSE AND RADIO
N.C. CONTACT. PHOTOCELLS
AND SAFETY EDGE
LIMIT SWITCH. CLOSE. N.C.
MAX. PERMITTED
LOAD:
1 PAIR PHOTOCELLS
1 RADIO RECEIVER
34
ALL OPERATIONS
OPEN, STOP & CLOSE
RADIO CONTACT
10 11 12 13 14 15 16 17 18
COMUNE
M1
230 V - 25 W
COURTESY LIGHT
SINGLE-PHASE MAX. 400W
ELECTRIC MOTOR
EARTH
MAX.
SUPPLY VOLTAGE
230 V - 25 W MAX.
FLASHING LAMP
6 exp
PC BOARD DRWG. 1795
230 V SINGLE-PHASE
STOP
IT IS ILLUMINATED WHEN
VOLTAGE IS SUPPLIED
OPEN
CLOSE
COMMON
1234
KEYSWITCH
PRIT 19
ELECTRICAL CONNECTIONS
KEYSWITCH PRIT 19
PIC. 16
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.
10
GARAGE DOOR OPERATOR COMPLETE WITH ALL THE RECOMMENDED ACCESSORIES
open
FOR A GOOD PERFORMANCE
230 VOLTS
MAINS SUPPLY
1
2
0
.
.F
I.T
1
9
8
7
6
5
4
3
O
2
T
1
S
E
N
3
IN
4
O
R
T
S
A
2
R
3
4
1
R
R
1
R
.
C
.
2
N
C
G
.
A
.
N
N
A
D
N
T
.
9
10
5
6
open
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
11
12
13
14
14 - RADIO TRANSMITTER ASTRO 43 TWO BUTTONS
PIC. 17
11
SPECIAL GARAGE DOORS
2˙500
SAFETY SWITCH
13 CEI
SINGLE-PHASE
400
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
CENTER
HINGES
UPPER HINGES
80 / 100 mm
ELECTRIC CABLE
LOOP LENGTH 1.30 m
SLIDING GUIDE
FOR ROLLER
REINFORCEMENT PLATE
100 x 5 mm
ROLLER WITH
SLIDING GUIDE
3˙000
2˙500
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
UPPER GUIDE
COUNTERWEIGHT
COUNTERWEIGHT
REINFORCEMENT PLATE
100 x 5 mm
IN THE MIDDLE OF THE DOOR
WARNING LAMP
ON STARTING
WITH RADIO AERIAL
UPPER ROLLER
FOR HORIZONTAL
UPPER TRACK
LOWER ROLLER SLIDING IN
THE LATERAL PERPENDICULAR
CASING
WALL FRAME
PIC. 20
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
UNSCREW BY ONE
TURN TO BLEED
AIR OUT OF THE
OIL TANK
“S”
IMPORTANT AFTER
INSTALLATION
APROLI 480
UNDO BY ONE TURN
“S”
OIL FADINI A 15 BY AGIP
STICKER FITTED TO THE OIL TANK
PIC. 21PIC. 19
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
- It is most important that the electric cables are removed from their terminals by loosening the fastening screws.
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.
ELECTRIC MOTOR
VOLTAGE SUPPLY
CABLE
ELECTRIC CABLE
PRESSURE SWITCH
NEVER CUT THE ELECTRIC CABLES
SAFETY EDGE
WITH PRESSURE
SWITCH
Never cut
the electric
- 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
TECHNICAL SPECIFICATIONS APROLI 480
480
1
2
3
4
5
FIXING
BRACKET
DOOR OPERATOR
LINEAR DESIGN
“M”
APROLI 480
ELECTRIC
TERMINAL
OUTPUT
LAMP AND
LAMP REFLECTOR
PROTECTION
COVER
12 34
91
®
PROLI
A
2 PHASE
330
230
1˙350
392.4
s.n.c.
HP (to use)
A
Hz
µF
4 MPa (40 Bar)
DATA STICKER
ELECTRIC MOTOR
Via Mantova, 177/A - 37053 Cerea (VR) Italy - Tel. 0442 330422 r.a. - Fax 0442 331054
MOTOR
W (absor.)
VOLTS
Rev/min.
Nm
Protection Standards IP 55
Max. working pressure
OIL FADINI A15 BY AGIP
MADE IN ITALY
4
0.33
1.8
50
12.5
80
56
LIGHT
6
7
DIFFUSION
TOP
COVER
BOTTOM
COVER
1˙610
“C” “A”
600
20 x 20
35
180
35
86
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
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
86
121
785
7
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
2
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
PIC. 23
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
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”.
10-2005
®
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.
The manufacturers reserve the right to change the products without any previous
notice and are not liable for possible damages to people and properties.
Distributor’s box
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
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