Page 1
Installation Instructions
Falcon Electro-mechanical
Swing Operator
Models: 8230 & 8240
640072-00(C) © 2012 Ingersoll-Rand Company Limited
Phone: 1-877-671-7011
Page 2
CONTENTS
General
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3. Wiring
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8. Falcon Software
11-12
GENERAL
The Falcon Operator is a low energy automatic electromechanical swinging door operator for
use on hinged, center pivoted and offset pivoted doors. When activated, the Falcon drives the
door to full open position, then electrical power is turned off and the door is closed by spring
force. The activating circuit opens the door from any position in the closing swing. During a
power failure, the Falcon Operator acts as a manual door closer (Size 3). Door opening and
closing cycles, including opening speed, back check speed, hold open time delay, closing
speed, latch position, and backcheck position are adjustable.
!
WARNING
Always disconnect main
power to the operator
prior to servicing
or cleaning.
!
CAUTION
This operator is for
indoor use only.
!
CAUTION
Do not mount any
accessories directly to
the operator.
2
2
3
4-5
6
6-7
8
9-10
11
REPLACEMENT PARTS & SYSTEM COMPONENTS
Part 26” Header
Control Box 8230-3462
8240-3462
Gear Box 8230-3454
8240-3454
Part Pull Standard Push Finish
Arm Assembly 8230-3077T 8240-3077 AL689
26” Pull System
(screw pack not shown)
Pull arm -3077T
and track -3038
Arm & track assy -3077PLCM
26” Push System
(screw pack not shown)
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Page 3
1. PRE-INSTALLATION SITE & PRODUCT CHECK
1.1 Check that the product model is correct for the required application.
1.2 Check that all parts listed on the Bill of Material are in the shipping container.
1.3 Check the architectural drawings and final approved shop drawings for the position
of frame and structural openings.
1.4 Check header and frame dimensions and required clearances.
26”
1/8” max reveal
26”
1.5 Check Door Width: 26” minimum for 26” Push Operator
30” minimum for 26” Pull Operator
1.6 Check that Door Weight is 200 lbs. or less. For heavier door, consult factory.
1.7 Check that a 115 volt, single phase, 60 Hz, fused 15 amp, 3-wire power supply is available
at the side jamb with approximately 12” of wire available to connect to the Operator.
UL approved flexible conduit is recommended for the 115 volt power line.
The 115 volt power supply must be a dedicated circuit from the main circuit breaker panel
and must NOT be connected into any building lighting system that operates florescent
lights.
Page 3 of 12
Page 4
2. OPERATOR INSTALLATION
2.1 Remove Control Box from Operator Mounting Bracket, then remove Motor/Gearbox from
Bracket:
26” Pull, 26” Push
1/4” - 20
Remove screw to remove control
box from mounting bracket
2.2 Prepare Header/Frame and Door: 26” Pull System..............................See below
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2.3 Install Operator Mounting Bracket on Header/Frame. Do not install the center screws
until you’ve attached the Motor Gearbox assembly in step 2.4
2.4 Install Motor/Gearbox on Operator Mounting Bracket. If there is not a mounting surface
for both screws on the Gearbox, use the ¼”-20 nut removed in 2.1 to secure the
gearbox. Then install the Control Box.
2.5 Proceed to Chapter 3: Wiring (page 6).
CAUTION
When mounting to an aluminum
26” Pull System
Header/Frame and Door Preparation
6”1/5-518”/3-9
frame, the use of rivet nuts is
strongly recommended.
Drill 1/2” hole in jamb
6
tube in this area for low
voltage wire access
1-11/16”
Page 4 of 12
Control
Box
Gearbox
24”
Page 5
2. OPERATOR INSTALLATION (CNTD)
26” Push System
Header/Frame and Door Preparation
6”1/5-518”/3-9
6
Control
Box
Gearbox
1-3/16”
5/8”
Drop Mount Application (26” Push System Only)
Header/Frame and Door Preparation
6”1/5-51
8”/3-9
4
Page 5 of 12
Page 6
3. WIRING
CAUTION
Make sure all wires are properly dressed and secured to prevent interference
Route all wiring away from moving parts, sharp edges, and heat sources
Use copper conductors only
Do not modify the factory wiring or connect into existing electrical circuits or devices
3.1 Refer to the appropriate wiring diagram for the Control Box (page 12) or the diagram
supplied for custom applications.
Connect the following cables:
Ground Cable (Ground the Operator properly with the earth from main supply)
Hall Effect Cable (Do not wrap the Hall Effect Cable around the Motor Power Cable)
Motor Power Cable (Do not wrap the Motor Power Cable around the Hall Effect Cable)
Control Box Power Cable
3.2 Connect activate and lock accessories, as needed.
Refer to the accessory instructions for any accessories used.
Do not connect any remote activating device to the door unless it is located within
line of sight of the door.
3.3 When wiring is complete, proceed to Chapter 4: Arm and Cover Installation (page 6)
4. ARM & COVER INSTALLATION
WARNING
Keep hands, clothing, wires, tools, etc., AWAY FROM Operator Motor
when the Operator Motor is turned on
4.1 Make sure the Operator Power is connected.
4.2 Install a jumper across the control box Main Act and Main Act Com.
4.3 The operator motor will activate and drive to the Full Open position, and remain there.
4.4 Push Arm Installation.
4.4.1 Open the door to 90˚, and attach the Main Arm to the operator spindle at 90˚ to the
opening (+/- 10˚) with the 8mm socket head screw (see fig. 1).
4.4.2 Remove the arm locking screw from the Rod & Shoe. Insert rod into forearm tube and
reinstall the arm locking screw loosely. Attach Rod & Shoe to door. With the door open to 90˚,
tighten the arm locking screw (see fig. 2).
8mm Socket
Head Screw
±10°
Fig. 1
Page 6 of 12
Arm Locking
Screw
Fig. 2
Page 7
4. ARM & COVER INSTALLATION (CNTD)
4.5 Pull Arm Installation
4.5.1 Slide the pull arm roller into the track, then insert a track end cap on each end of the
track and install track to door.
4.5.2 Attach the Pull Arm to the track roller with the roller locking screw and to the operator
spindle loosely with the 8mm socket head screw. Open the door to 90°, and tighten the 8mm
socket head screw (see fig. 3).
4.5.3 Attach arm if required. Due to the mesh of the arm to operator spindle, the door may be
open to slightly more or less than 90°. To adjust arm, remove arm adjustment screws, push
door open to 90° and reinstall arm screws (see fig. 4).
Pull Arm
Arm Locking
Screw
8mm Socket
Head Screw
Arm Adjustment
Screws
Fig. 3
Fig. 4
4.6 Remove the jumper from the control box Main Act and Main Act Com. The door should close.
4.7 Connect actuator wiring as required (see page 12).
4.8 Test the operator. (See Chapter 5: Operational Check on page 8)
4.9 Adjust the operator as required. (See Chapter 6: Operator Adustment on page 9)
4.10 Install the cover assembly onto the operator.
4.11 Release the operator for service. (See Chapter 7: Release for Service on page 11)
Page 7 of 12
Page 8
5. OPERATIONAL CHECK
5.1 Activate the operator using the activation device.
The operator will perform one sizing cycle.
Sizing Cycle: Occurs after power is turned on and a legitimate activation signal
is received. During the sizing cycle, the door opens and closes one time.
5.2 If the door does NOT OPEN AT ALL during the sizing cycle:
• Check the door for binding.
• If an electromechanical lock is being used, check that the lock disengages before the
operator opens the door.
• Check fuses, circuit breakers and connections.
• Adjust the operator and check the door operation
(See chapter 6: Operator Adjustment on
Below are default settings:
Opening Speed 9:00
Back Check Speed 3:00
Hold Open Time Delay 10:00
Latch Position 12:00
Closing Speed 12:00
Back check position 4:00 (Fully clockwise)
page 9)
5.3 If the door does NOT OPEN FULLY during the sizing cycle:
• Check the door for binding.
• Increase the back check speed slightly and re-check the door operation.
Repeat until door opens fully.
5.4 If the door OPENS TOO FAST during the sizing cycle, decrease the back check speed
slightly and re-check the door operation. Repeat until the door opens at desired speed.
5.5
After the sizing cycle is completed and the door(s) are closed, apply a maintained
activation signal. Check that the door remains open while the signal is applied.
5.7 When the door is operating properly, continue with Step 4.11 on
page 7.
Page 8 of 12
Page 9
6. OPERATOR ADJUSTMENT
See table below and diagrams (page 10) for operator feature adjustment.
After adjusting, cycle the door several times to check for proper operation.
NOTE
Adjust Operator for the SLOWEST operation practical, in accordance with the latest
revisions of the Americans with Disabilities Act (ADA); ANSI/BHMA A156.19 Standards
for Power-Assisted and Low Energy Power-Operated Doors; and local codes.
Opening Speed: 5 seconds or more Latch Location: 10 degrees or more
Closing Speed: 3 seconds or more Latch Speed: 1.5 seconds or more
Features Control Description Counter
Clockwise
Opening
Speed
Back Check
Speed
Opening
Speed
Back Check
Speed
Controls opening speed of door Slower Faster
Controls the speed of the door
Slower Faster
near the full open position to
prevent door slamming
Hold Open
Time Delay
Back Check
Position
Hold Open
Time Delay
Back Check
Position
Controls the length of time the
door remains in the full open
position: 1 sec to 30 sec
Door position where back check
speed engages
Less Time
Down to
1 sec
Less
Pressure
Required
Latch
Position
Latch
Position
Door position at which
deceleration towards full closed
Less
Latch
begins in order to prevent door
slamming
Closing
Speed
Closing
Speed
Controls closing speed of door Slower Faster
Clockwise
More Time
Up to
30 sec
More
Pressure
Required
More Latch
Delayed
DLY ON: Delays opening of door for
Activation
Push and
PNG ON: Pushing the door open 5°
Go
Page 9 of 12
strike applications (1 second
delay)
causes operator to open door
for remainder of open cycle
Page 10
6. OPERATOR ADJUSTMENT (CNTD)
Fuse
Fuse
Main
Power
12 VAC
Power
Motor
Delay
On
Off
Open
Speed
Delay
Back
Check
Speed
Speed
Open
Back
Check
Pos
Speed
Check
Back
Close
Speed
Pos
Check
Back
Latch
Pos
Speed
Close
Hold
Open
Pos
Latch
Push
-nGo
Open
Hold
On
Off
Go
-nPush
Page 10 of 12
Page 11
7. RELEASE FOR SERVICE
7.1 Remove all tools, installation equipment and debris from the vicinity of the door.
7.2 MANDATORY: Install all Safety, Traffic Control and Instruction Labels onto the door,
as required.
Failure to do this will leave the INSTALLER LIABLE for any accidents that occur.
7.3 Give verbal instruction on how to properly operate the door to the owner or
person in charge.
7.4 Give verbal instruction to the owner or person in charge on periodic inspection of the
door for the following:
• Occasional damage
• Developing problems
• Minor preventative maintenance
7.5 Provide the owner or person in charge with a contact name and phone number to call
for future service and maintenance.
Be sure to install all Safety, Traffic Control and Instruction Labels
8.1 Operation:
8.1.1 Sizing
From start-up (Sizing), the door will activate via:
Main Input (Main Act and Main Act Com).
The first motion of the door will be towards the Door Open position. The speed during
Sizing is automatic and cannot be set from a potentiometer.
The door drives to full open and the system sets the open counter to full open.
The door closes at Closing Speed. The system sets the closed counter to Full Closed
when the latch goes up at the Closed position.
IMPORTANT
onto the door, as required
8. FALCON SOFTWARE
The system calculates all other parameters required for normal operation based on the
two values of Full Open and Full Closed.
Page 11 of 12
Page 12
8.1.2 Standard Operation
Upon a legitimate activation signal, the door accelerates to opening speed while
monitoring the current load on the drive output. If the current exceeds the specified
level, the door will stop and close.
The door travels at it’s set speed (based on the potentiometer setting) until it reaches
the Back Check position, where it will decelerate to the Back Check Speed.
The door will stop at the Hold Open position and remain there until an activation or the
Hold Open Timer is cleared.
The door then closes at its Closing Speed (based on the potentiometer setting) up to the
latched position.
If the Closing Speed is decreased by driving the motor in the open direction (a fixed
setting), power is added to allow the spring to continue closing the door to the Full
Closed position.
8.2 Wiring
8. FALCON SOFTWARE (CNTD)
For clarity, not all
components are shown
J8, 10-position
Control Box Power Cable
J1, 6-position
Main Power Cable
on the control box PC board
J5, 2-position
Motor Power Cable
J3, 4-position
Hall Effect Cable
120VAC
Input
Page 12 of 12
Plug cables into
these receptacles
External
24 VDC
Power Supply
12VAC
12VAC
Safety Sen
Safety GND
Main Act
Main Act Com
Relay N/O
Relay Com
Relay N/C
24VDC +
24VDC -
should be connected in parallel
Black DC-
Depending on Device
Connect
Fail Safe to Relay N/C
Fail Secure to Relay N/O
Control box
grounding stud
Multiple activation devices
Activation Device
N/O Dry Contacts
Electric Lock,
Electric Strike, etc.
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