Nice Hansa Robus 250, Robus 500 Instructions And Warnings For Installation And Use
NiceHansa Robus
Instructions and warnings for installation and use
250 / 500
2 – English
1) Warnings
This manual contains important information regarding safety. Before
you start installing the components, it is important that you read all the
information contained herein. Store this manual safely for future use.
Due to the dangers which may arise during both the installation and
use of the NiceHansa Robus, installation must be carried out in full
respect of the laws, provisions and rules currently in force in order to
ensure maximum safety. This chapter provides details of general warnings. Other, more specific warnings are detailed in Chapters “3.1 Preliminary Checks” and “5 Testing and Commissioning”.
According to the most recent European legislation, the
automation of doors or gates is governed by the provisions
listed in Directive 98/37/CE (Machine Directive) and, more
specifically, to provisions: EN 13241-1 (harmonised standard); EN 12445; EN 12453 and EN 12635, which enables to
declare the conformity to the machine directive.
Please access “www.niceforyou.com” for further information, and
guidelines for risk analysis and how to draw up the Technical Documentation. This manual has been especially written for use by qualified
fitters. Except for the enclosed specification “Instructions and Warnings for Users of the NiceHansa Robus gearmotor” which is to be
removed by the installer, none of the information provided in this manual can be considered as being of interest to end users!
• Any use or operation of NiceHansa Robus which is not explicitly pro-
vided for in these instructions is not permitted. Improper use may
cause damage and personal injury.
• Risk analysis must be carried out before starting installation, to
include the list of essential safety requisites provided for in Enclosure
I of the Machine Directive, indicating the relative solutions employed.
Risk analysis is one of the documents included in the “Technical
Documentation” for this automation.
• Check whether additional devices are needed to complete the
automation with NiceHansa Robus based on the specific application
requirements and dangers present. The following risks must be considered: impact, crushing, shearing, dragging, etc. as well as other
general dangers.
• Do not modify any components unless such action is specified in this
manual. Operations of this type are likely to lead to malfunctions.
NICE disclaims any liability for damage resulting from modified products.
• During installation and use, ensure that solid objects or liquids do not
penetrate inside the control unit or other open devices. If necessary,
please contact the NICE customer service department; the use of
NiceHansa Robus in these conditions can be dangerous.
• The automation system must not be used until it has been commis-
sioned as described in chapter 5 “Testing and commissioning”.
• The NiceHansa Robus packing materials must be disposed of in
compliance with local regulations.
• If a fault occurs that cannot be solved using the information provided
in this manual, refer to the NICE customer service department.
• In the event that any automatic switches are tripped or fuses blown,
you must identify the fault and eliminate it.
• Disconnect all the power supply circuits before accessing the termi-
nals inside the NiceHansa Robus cover. If the disconnection device
is not identifiable, post the following sign on it: “WARNING: MAINTENANCE WORK IN PROGRESS”.
• Only connect the control unit to a power supply line equipped with a
safety grounding system.
• The power supply line must be protected by circuit breakers.
• An isolator must be inserted in the power supply line from the electri-
cal mains mounted near the automation and must have a locking
system preventing unintentional unauthorized connection.
!
Particular warnings concerning the suitable use of this product in relation to the 98/37CE “Machine Directive” (ex 89/392/EEC):
• This product comes onto the market as a “machine component” and
is therefore manufactured to be integrated to a machine or assembled with other machines in order to create “a machine”, under the
directive 98/37/EC, only in combination with other components and
in the manner described in the present instructions manual. As specified in the directive 98/37CE the use of this product is not admitted
until the manufacturer of the machine on which this product is
mounted has identified and declared it as conforming to the directive
98/37/CE.
Particular warnings concerning the suitable use of this product in relation to the 73/23/EEC “Low Voltage” Directive and subsequent modification 93/68/EEC:
• This product responds to the provisions foreseen by the “Low Voltage” Directive if used in the configurations foreseen in this instructions manual and in combination with the articles present in the Nice
S.p.a. product catalogue. If the product is not used in configurations
or is used with other products that have not been foreseen, the
requirements may not be guaranteed; the use of the product is prohibited in these situation until the correspondence with the requirements foreseen by the directive have been verified by installers.
Particular warnings concerning the suitable use of this product in relation to the 89/336/EEC “Electromagnetic Compatibility” Directive and
subsequent modifications 92/31/EEC and 93/68/EEC:
• This product has been subjected to tests regarding the electromagnetic compatibility in the most critical of use conditions, in the configurations foreseen in this instructions manual and in combination with
articles present in the Nice S.p.A. product catalogue. The electromagnetic compatibility may not be guaranteed if used in configurations or with other products that have not been foreseen the use of
the product is prohibited in these situations until the correspondence
to the requirements foreseen by the directive have been verified by
those performing the installation.
English – 3
2) Product description and applications
NiceHansa Robus is a line of irreversible electromechanical gearmotors for the automation of sliding gates. It is equipped with an electronic control unit and connector for the optional SMXI radiocontrol receiver. The electrical connections to external devices have been simplified
through the use of “BlueBUS”, a technique by which several devices
can be connected up using just 2 wires. NiceHansa Robus operates
with electric power. In the event of a power failure, the gearmotor can
be released using a special key in order to move the gate manually.
Alternatively, there is the PS124 buffer battery (optional accessory)
which makes it possible to use the gate also during the event of a power failure.
Other products are also part of the NiceHansa Robus line, the difference of which is described in table 1.
Note: 1 kgf = 9,81N for example: 600 N = 61 kgf
Gearmotor type RB250 RB500
Limit switch type electromechanical
Maximum leaf length 8 m 8 m
Maximum leaf weight 250 kg 500 kg
Peak torque 9,3 Nm 13 Nm
corresponding to a force) 310 N 360 N
Motor and transformer Motor 24 Vcc
EI core-type transformer
Table 1: comparison of the NiceHansa Robus gearmotor main characteristics
1
2.1) Operating limits
Chapter 8 “Technical Characteristics” provides the only data needed to
determine whether the products of the NiceHansa Robus line are suitable for the intended application.
The structural characteristics of NiceHansa Robus make it suitable for
use on sliding leaves in conformity with the limits indicated in tables 2, 3
and 4.
The effective suitability of NiceHansa Robus to automate a particular
sliding gate depends on the friction as well as other correlated factors,
such as ice, that could interfere with the movement of the leaf.
For an effective control it is absolutely vital to measure the force necessary to move the leaf throughout its entire run and ensure that this is
less than half of the “nominal torque” indicated in chapter 8 “Technical
characteristics” (a 50% margin on the force is recommended, as
unfavourable climatic conditions may cause an increase in the friction);
furthermore, it is necessary to take into consideration the data indicated in tables 2 and 3 to establish the number of cycles/hour, consecutive cycles and maximum speed allowed.
330 mm 210 mm
303 mm
98 mm
330 mm 195 mm
277 mm
85 mm
RB250
RB500
RB250 - RB500
Leave width (m) max. cycle/hour
max. no. of consecutive cycles
Up to 4 40 20
4 ÷ 6 25 13
6 ÷ 8 20 10
8 ÷ 10 --- ---
10 ÷ 12 --- ---
Table 2: limits in relation to the length of the leaf
RB250 - RB500
Leaf weight (kg) % cycles Maximum speedallowed
Up to 200 100% V6 = Extremely fast
200 ÷ 400 80 V5 = Very fast
400 ÷ 500 60 V4 = Fast
500 ÷ 600 50 V3 = Medium
600 ÷ 800 --- ---
800 ÷ 900 --- ---
900 ÷ 1000 --- ---
Table 3: limits in relation to the weight of the leaf
Severity index % RB250 - RB500 Durability in cycles
Leaf weight Kg
Up to 200 10
200 ÷ 400 30
400 ÷ 600 50
600 ÷ 700 ---
700 ÷ 800 ---
800 ÷ 900 ---
900 ÷ 1000 ---
Leaf length m
Up to 4 10
4 ÷ 6 20
6 ÷ 8 35
8 ÷ 10 ---
10 ÷ 12 ---
Other stress related elements
(to be taken into consideration if the probability that
they occur is greater than 10% )
Surrounding temperature greater than 40°C
or lower than 0°C or humidity greater than 80%
10
Presence of dust and sand 15
Presence of salinity 20
Photo manoeuvre interruption 15
Stop manoeuvre interruption 25
Speed greater than “L4 fast” 20
Thrust active 25
Severity index total%:
Note: if the severity index exceeds 100%, this means that the conditions are beyond the acceptable limits; a larger model is therefore advised.
4 – English
Table 4: durability estimate in relation to the manoeuvre severity index
Severity index %
Durability in cycles
The length of the leaf makes it possible to determine both the maximum number of cycles per hour and consecutive cycles, while the
weight makes it possible to determine the reduction percentage of the
cycles and the maximum speed allowed. For example, for RB 500 if
the leaf is 5 m long it will be possible to have 25 cycles/hour and 13
consecutive cycles. However, if the leaf weighs 500 Kg, they must be
reduced to 75%, resulting in 15 cycles/hour and 7 consecutive cycles,
while the maximum speed allowed is V4: fast. The control unit has a
limiting device which prevents the risk of overheating based on the
load of the motor and duration of the cycles. This device triggers when
the maximum limit is exceeded. The manoeuvre limiting device also
measures the ambient temperature reducing the manoeuvre further
when the temperature is particularly high.
The “durability” estimate is shown in chapter 8 “Technical characteristics”, which is the average useful life of the product. The value is deeply
influenced by the severity index of the manoeuvre, this being the sum
of all factors that contribute to wear. To perform this estimate, all severity indexes in table 4 must be totalled, then the estimated durability in
the graph must be checked with the total result.
For example, when RB 500 is fitted to a gate weighing 360 Kg and 4m
in length, equipped with photocells and without other stress related
elements, it obtains a severity index equal to 55% (30+10+15). From
the graph the estimated durability is equal to 70,000 cycles.
English – 5
2.2) Typical System
Figure 2 shows a typical system for automating a sliding gate using NiceHansa Robus
1 Key-operated selector switch 6 “Open” stop bracket 11 “Closed” stop bracket
2 Photocells on post 7 Rack 12 Secondary movable edge (optional)
3 Photocells 8 Secondary fixed edge (optional) 13 Radio-transmitter
4 Main fixed edge (optional) 9 Flashing light with incorporated aerial 14 Circuit breaker
5 Main movable edge 10 NiceHansa Robus
2
43 38
10
2
6
11
7
9
13
1251
EC CF
D
F
14 A
B
2.3) List of cables
Figure 2 shows the cables needed for the connection of the devices in
a typical installation; table 5 shows the cable characteristics.
The cables used must be suitable for the type of installation;
for example, an H03VV-F type cable is recommended for indoor
applications, while H07RN-F is suitable for outdoor applications.
!
Note 1: power supply cable longer than 30 m may be used provided it has a larger gauge, e.g. 3x2,5mm2, and that a safety grounding system
is provided near the automation unit.
Note 2: If the “BLUEBUS” cable is longer than 30 m, up to 50 m, a 2x1mm
2
cable is needed.
Note 3: A single 2x0,5mm
2
cable can be used instead of two 4x0,5mm2cables.
Note 4: Please refer to Chapter “7.3.2 STOP Input” in situations where there is more than one edge, for information about the type of connec-
tion recommended by the manufacturer.
Note 5: special devices which enable connection even when the leaf is moving must be used to connect movable edges to sliding leaves.
Connection Cable type Maximum length allowed
A: Power line 1 3x1,5mm2 cable 30m (note 1)
B: Flashing light with aerial 1 2x0,5mm2cable 20m
1 RG58 type shielded cable 20m (recommended less than 5 m)
C: Photocells 1 2x0,5mm2 cable 30m (note 2)
D: Key-operated selector switch 2 2x0,5mm2 cable (note 3) 50m
E: Fixed edges 1 2x0,5mm2 cable (note 4) 30m
F: Movable edges 1 2x0,5mm2 cable (note 4) 30m (note 5)
Table 5: List of cables
6 – English
3) Installation
The installation of NiceHansa Robus must be carried out by
qualified personnel in compliance with current legislation, stan-
!
dards and regulations, and the directions provided in this manual.
3.1) Preliminary checks
Before proceeding with the installation of NiceHansa Robus you must:
•Check that all the materials are in excellent condition, suitable for use
and that they conform to the standards currently in force.
• Make sure that the structure of the gate is suitable for automation.
• Make sure that the weight and dimensions of the leaf fall within the
specified operating limits provided in chapter “2.1 Operating limits”.
• Check that the force required to start the movement of the leaf is less
than half the “maximum torque”, and that the force required to keep
the leaf in movement is less than half the “nominal torque”. Compare
the resulting values with those specified in Chapter “8 Technical
Characteristics”. The manufacturers recommend a 50% margin on
the force, as unfavourable climatic conditions may cause an increase
in the friction.
• Make sure that there are no points of greater friction in the opening
or closing travel of the gate leaves.
• Make sure there is no danger of the gate derailing.
• Make sure that the mechanical stops are sturdy enough and that
there is no risk of the deformation even when the leaf hits the
mechanical stop violently.
• Make sure that the gate is well balanced: it must not move by itself
when it is placed in any position.
•Make sure that the area where the gearmotor is fixed is not subject to
flooding. If necessary, mount the gearmotor raised from the ground.
• Make sure that the installation area enables the release of the gearmotor and that it is safe and easy to release it.
• Make sure that the mounting positions of the various devices are
protected from impacts and that the mounting surfaces are sufficiently sturdy.
• Components must never be immersed in water or other liquids.
• Keep NiceHansa Robus away from heat sources and open flames; in
acid, saline or potentially explosive atmosphere; this could damage
NiceHansa Robus and cause malfunctions or dangerous situations.
• If there is an access door in the leaf, or within the range of movement
of the gate, make sure that it does not obstruct normal travel. Mount
a suitable interblock system if necessary.
• Only connect the control unit to a power supply line equipped with a
safety grounding system.
• The power supply line must be protected by suitable magneto-thermal and differential switches.
• A disconnection device must be inserted in the power supply line
from the electrical mains (the distance between the contacts must be
at least 3.5 mm with an overvoltage category of III) or equivalent system, for example an outlet and relative plug. If the disconnection
device for the power supply is not mounted near the automation, it
must have a locking system to prevent unintentional, unauthorised
connection.
3.2) Installation of the gearmotor
The gearmotor must be fastened directly to an already existing mounting surface using suitable means, for example expansion screw
anchors. Otherwise, in order to fasten the gearmotor the installer must:
1. Dig a foundation hole with suitable dimensions referring to Figure 3.
2. Prepare one or more conduits for the electrical cables as shown in
figure 4.
3. Assemble the two clamps on the foundation plate setting one nut
underneath and one on top of the plate. The nut underneath the
plate must be as shown in Figure 5 screwed so that the threaded
part protrudes above the plate by approximately 25÷35 mm.
4. Pour the concrete and, before it starts to harden, set the foundation
plate to the values shown in Figure 3. Check that it is parallel to the
leaf and perfectly level (Figure 6). Wait for the concrete to harden
completely.
5. Remove the 2 upper nuts of the plate and then place the gearmotor
onto them. Check that it is perfectly parallel to the leaf, then screw
the two nuts and washers supplied, as shown in Figure 7.
3
4
5
6
25÷35
7
192
330 0÷50
0÷50 330
192
0÷10
0÷10
English – 7
If the rack is already present, once the gearmotor has been fastened,
use the adjustment dowels as shown in Figure 8 to set the pinion of
NiceHansa Robus to the right height, leaving 1÷2 mm of play from the
rack. Otherwise, in order to fasten the rack the installer must:
6. Release the gearmotor as shown in “Release and manual move-
ment” paragraph in the Chapter “Instructions and Warnings for
users of the NiceHansa Robus gearmotor”.
7. Open the leaf up completely and place the first piece of the rack on
the pinion. Check that the beginning of the rack corresponds to the
beginning of the leaf, as shown in Figure 9. Leave a 1÷2 mm play
between the rack and the pinion, then fasten the rack to the leaf
using suitable means.
3.3) Fixing of the limit switch bracket on versions
with inductive limit switch
The limit switch bracket must be fixed as described below for the
RB250 and RB500 versions that utilise the inductive limit switch.
1. Manually place the leaf in the open position leaving at least
2-3 cm from the mechanical stop.
2. Slide the bracket along the rack in the opening direction until the
corresponding LED switches off, as in fig. 13. Then bring the bracket forward by at least 2 cm and secure it to the rack with the appropriate dowels.
3. Manually place the leaf in the closed position leaving at least 2-3 cm
from the mechanical stop
4. Slide the bracket along the rack in the closing direction until the cor-
responding LED switches off. Then bring the bracket forward by at
least 2 cm and secure it to the rack with the appropriate dowels.
The ideal distance of the bracket for inductive limit switches
is between 3 and 8 mm as indicated in fig. 14.
!
In order to prevent the weight of the leaf from affecting the
gearmotor, it is important that there is a play of 1÷2 mm between
the rack and the pinion as shown in Figure 10.
8.
Slide the leaf, using the pinion as a reference point for the fastening the
other elements of the rack.
9.
Cut away the exceeding part of the rack.
10.
Open and close the gate several times and make sure that the rack is
aligned with the pinion with a maximum tolerance of 5 mm. Moreover,
check that the play of 1÷2 mm has been respected along the entire
length between the pinion and the rack.
11.
Thoroughly tighten the two fixing nuts of the gearmotor making sure it
is well fastened to the ground. Cover the fixing nuts with the relative
caps as shown in figure 11.
!
12.
Fix the limit switch bracket as described below (for versions RB250P
and RB500P, fix the bracket as described in paragraph “3.3 Fixing of
the limit switch bracket on versions with inductive limit switch”):
• Manually place the leaf in the open position leaving at least 2-3 cm
from the mechanical stop.
• Slide the bracket along the rack in the opening direction until the limit switch cuts-in. Then bring the bracket forward by at least 2 cm
and secure it to the rack with the appropriate dowels, as in fig. 12.
• Perform the same operation for the closure limit switch.
13. Lock the gearmotor as shown in “Release and manual movement”
paragraph in the Chapter “Instructions and Warnings for Users”
8 9 10
11 12
1÷2
13
14
3÷8
8 – English
3.4) Installation of the various devices
If other devices are needed, install them following the directions provided in the corresponding instructions. Check this in paragraph “3.6
Description of electrical connections” and the devices which can be
connected to the NiceHansa Robus in Figure 2.
3.5) Electrical connections
Only carry out electrical connections once the electricity
supply to the system has been switched off. Disconnect any
buffer batteries present.
1. Remove the protection cover in order to access the electronic control unit of the
NiceHansa Robus. The side screw must be removed, and the cover lifted
upwards.
2. Remove the rubber membrane which closes the hole for passage of the
cables and insert all the connection cables towards the various devices,
leaving a length of 20÷30 cm longer than necessary. See Table 5 for information regarding the type of cables and Figure 2 for the connections.
3. Use a clamp to collect together and join the cables which enter the gear-
motor. Place the clamp just underneath the hole the cables enter through.
!
Make a hole in the rubber membrane which is slightly smaller than the
diameter of the cables which have been collected together, and insert the
membrane along the cables until you reach the clamp. Then put the membrane back in the slot of the hole the cables pass through. Lay a second
clamp for collecting the cables which are set just above the membrane.
4. Connect the power cable to the appropriate terminal as shown in figure 15,
then block the cable at the first cable block ring using the clamp.
5. Connect up the other cables according to the diagram in Figure 17. The ter-
minals can be removed in order to make this work easier.
6.
Once the connections have been completed, block the cables collected in the
second cable block ring using clamps. The excess of the aerial cable must be
blocked to the other cables using another clamp as shown in Figure 16.
15
17
16
See paragraph “7.3.5 NiceHansa Robus in Slave mode” for the connection of 2 motors on opposite leaves.
LUCYB
S.C.A.
MOFB MOSE
OPEN CLOSE
English – 9
3.6) Description of the electrical connections
The following is a brief description of the electrical connections; for
further information please read “7.3 Adding or Removing Devices”
paragraph.
FLASH: output for one or two “LUCYB” or similar type flashing lights
with single 12V maximum 21W bulb.
S.C.A.: “Open Gate Light” output. An indication lamp can be connected (24V max. 4W). It can also be programmed for other functions; see paragraph “7.2.3 Level two functions”.
BLUEBUS: compatible devices can be connected up to this terminal.
They are connected in parallel using two conductors only, through
which both the electricity supply and the communication signals travel. For more useful information about BlueBUS see also Paragraph
“7.3.1 BlueBUS”.
STOP: input for the devices which block or eventually stop the
manoeuvre in progress. Contacts like “Normally Closed”, “Normally
Open” or constant resistance devices can be connected up using
special procedures on the input. For more useful information about
STOP see also Paragraph “7.3.2 STOP Input”.
STEP-BY-STEP: input for devices which control Step-by-Step movement. It is possible to connect “Normally Open” devices up to this
input.
OPEN: input for devices which control only the opening movement. It
is possible to connect “Normally Open” devices up to this input.
CLOSE: input for devices which control only the closing movement.
It is possible to connect “Normally Open” devices up to this input.
AERIAL: connection input for the radio receiver aerial (the aerial is
incorporated in LUCY B).
4) Final checks and start up
The manufacturers recommend you position the leaf at approximately
half travel before starting the checking and start up phase of the
automation. This will ensure the leaf is free to move both during opening and closure.
4.1) Choosing the direction
The direction of the opening manoeuvre must be chosen depending
on the position of the gearmotor with respect to the leaf. If the leaf
must move left for opening, the selector must be moved towards left
as shown in Figure 18; alternatively, if the leaf has to move right during
opening, the selector must be moved towards the right as shown in
Figure 19
4.2) Power supply connection
The connection of NiceHansa Robus to the mains must
be made by qualified and experienced personnel in possession of the necessary requisites and in full respect of the
laws, provisions and standards currently in force.
As soon as NiceHansa Robus is energized, you should check the following:
1. Make sure that the “BLUEBUS” LED flashes regularly, with about
one flash per second.
2. Make sure that the LED’s on the photocells flash (both on TX and
RX); the type of flashing is not important as it depends on other fac-
!
tors.
3. Make sure that the flashing light connected to the FLASH output
and the lamp LED connected to the “Open Gate Indicator” output
are off.
If the above conditions are not satisfied, you should immediately switch
off the power supply to the control unit and check the electrical connections more carefully.
Please refer to Chapter “7.6 Troubleshooting” for further information
about finding and analysing failures.
18
19
4.3) Recognition of the devices
After connecting up the power supply, the control unit must be made
to recognise the devices connected up to the BLUEBUS and STOP
inputs. Before this phase, LEDs L1 and L2 will flash to indicate that
recognition of the devices must be carried out.
1. Press keys [▲] and [Set] and hold them down
2. Release the keys when L1 and L2 LED’s start flashing very quickly (after approx. 3 s)
3. Wait a few seconds for the control unit to finish recognizing the devices
4. When the recognition stage is completed the STOP LED must remain on while the
L1 and L2 LED’s must go off (LEDs L3 and L4 will eventually start flashing).
20
The connected devices recognition stage can be repeated at any time, even after the installation (for example, if a device is installed); for performing the new recognition see paragraph “7.3.6 Recognition of Other Devices”.
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