BOXTER
AUTOMATION FOR OVERHEAD GARAGE DOORS
USE AND MAINTENANCE MANUAL
V01_2011
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QK-B24
QK-B220
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C O N T E N T S
TECHNICAL FEATURES 2
DIMENSION OF GEARMOTOR 2
PRE-INSTALLATION CONTROL 2
MATERIALS FOR INSTALLATION 3
FIXING THE LONGITUDINAL FRAME MEMBER 3
MEASURES TO BE RESPECTED 4
INSTALLING THE GEARMOTOR 5
INSTALLATION OF TRANSMISSION AXES FOR CENTRAL SINGLE MOTOR 5
INSTALLING THE TELESCOPIC ARMS 6
ADJUSTING THE END-LIMIT SWITCHES 6
MANUAL UNLOCK 7
SOME GENERAL ADVICE 7
TYPICAL SYSTEM 8
USE 9
MAINTENANCE 9
TILTING GATES INSTALLATION GUIDE 10
MAINTENANCE RECORD BOOK 17
DECLARATION OF COMPLIANCE (1) 19
DECLARATION OF COMPLIANCE (2) 20
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TECHNICAL FEATURES
PRE-INSTALLATION CONTROL
Before installing the automation, you must check that:
- all structural changes must be implemented to realize safety freeboards;
- the existing structure must comply with the necessary sturdiness and stability criteria;
Quiko Italy Sas is liable only for products it manufactures and commercializes. Once automated, the gate
becomes a machine and is therefore subjected to the rules of the “ Machinery Directive”. It is on the installer to
verify its security. WARNING: Quiko Italy Sas is not liable for any damages to people, animals or things due
to unauthorised modi
ons, alterations or betterments on its products by third parties.
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TECHNICAL FEATURES
QK-B220
QK-B220Q
QK-B24
QK-B24Q
Power 230Vac 50Hz 24Vdc
Power absorbed (W) 250 80
Protection level (IP) 44
Reduction ratio 1/820
Opening time (s) 15
Work cycle (%) 60 100
Motor weight (kg) 9,5
Insulation class F
Thermal cut-out (°C) 140 -
Built-in control board - -
3
MATERIALS FOR INSTALLATION
CENTRAL SINGLE MOTOR LATERAL DOUBLE MOTOR
1. 1600 mm longitudinal frame member;
2. bossed driving shaft;
3. straight,telescopic arm,complete with:
upper fitting;
fitting.axis;
4. M8 x 25 galvanized screw;
5. M8 self-locking nut;
6. M6 x 120 galvanized screws;
7. flat was hers;
8. M6 self-locking nuts;
9. gearmotor.
1. 1600 mm longitudinal frame member;
2. straight, bossed telescopic arm
(25/50mm) with upper fitting;
3. curved bossed telescopic arm
(25/50mm) with upper fitting;
4. M8 x 25 galvanized screw;
5. M8 self-locking nut;
6. M6 x 120 galvanized screws;
7. flat was hers;
8. M6 self-locking nuts;
9. gearmotors.
FIXING THE LONGITUDINAL FRAME MEMBER
1. Arrange the side members slightly off in
relation to the handle;
2. anchor it to the frame of the tilting gates
by means of thread-cutting screws.
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MEASURES TO BE RESPECTED
INSTALLATION OF CENTRAL SINGLE
MOTOR
INSTALLATION OF LATERAL DOUBLE
MOTOR
In both central single motor and lateral double motor, the condition described in the figure is equally
defined.
SUPPORTING FRAME
UP & OVER DOOR
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INSTALLING THE GEARMOTOR
1. Valuate the anchoring position of
the gear motor based on the
dimensions shown in the figure;
2. fasten the stud-bolt with the
relative washer and tighten the
nuts.
INSTALLATION OF TRANSMISSION AXES FOR CENTRAL SINGLE MOTOR
1. After having cut the transmission axes to the
agreed length, fasten them to the shaft of the
gear motor by means of proper pegs;
2. anchor the axial fittings to the frame of the tilting
gate by means of thread-cutting screws.
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INSTALLING THE TELESCOPIC ARMS
CENTRAL SINGLE MOTOR
LATERAL DOUBLE MOTOR
1. Cut the components of the telescopic arms
and anchor them to the transmission axis.
1. Cut the components of the telescopic arms
and anchor them.
ADJUSTING THE END-LIMIT SWITCHES
In case the installed automation is made up by a centralmotor, the stroke of the tilting gate is adjusted by acting on
the stops (1), and by rotating them in the ring that seats
them (2).
In case the installed automation is made up of 2 lateral
motors, the procedure is the same, but the adjustment will
only be performed in the gear motor with the unit.
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MANUAL UNLOCK
Integrate the safety device relative to the tilting gate in compliance with the local norm. Choose short
routes for cables and keep power cables separate from control ones. Install the control card in a
waterproof box. For the precision adjustment of the gear motor’s maximum torque, comply with the
local norms. In compliance with the European norm relative to safety, it is advised to introduce an
external
switch to remove power during maintenance of the tilting gate. Check that each single
installed device is ecient and eective. Ax easily readable signs that inform about the presence of
the motorized tilting gate.
The dimensions of the rods, the position of the reciprocal levers and the wall tting of the arms’
support bell crank, must be established so as the motor’s arms do not touch with the support arms of
the tilting
gate. W hen it is not possible to avoid that the straight motor’s arms come into contact with
the tilting gate, use the curved motor’s arms.
After having installed the motor/s on the tilting gate, release them and check that the tilting gate can
be manually enabled easily. In case the tilting gate is too heavy, it is necessary to increase the
counterweights until the frame is completely balanced.
To enable the manual release, introduce the key in the
unblocking spindle and rotate it about 90° clockwise, as shown
in the figure.
Thanks to the external manual release available on request, it is also possible to enable the manual
release from the exterior by rotating the handle of the tilting gate; a metallic thread will enable the
release by rotating the lever located above the cam.
SOME GENERAL ADVICE
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TYPICAL SYSTEM
MAIN COMPONENTS
1 – GEARMOTOR
2 – KEY SELECTOR
3 – SWITCH
4 – FLASHING LIGHT
5 – PNEUMATIC EDGE
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USE
T he gear motors located in the automation have a long life; nonetheless, their regular functioning can
be jeopardized by the state of the tilting gate.
Therefore we describe a few operations to maintain the tilting gate ecient.
Warning: Non-specialized sta cannot operate the gate during maintenance. You are advised to cut
the network power in order to avoid accidents or shocks. If the power must be on for various
inspection
s, you are advised to check and/or deactivate any possible control devices (remote
controls, keyboards, etc…) except for the devise used by the maintenance operator.
Routine maintenance
Each of the following operations must be done when needed and in all cases at least every
6 months
- clean and lubricate the moving parts;
- check the stability of the automatism and the tightness of all screws;
- check the gate stability and that the movement is normal with no fr
ictions;
- check the correct functioning of all command and safety functions.
Extraordinary Maintenance
If special maintenance is required for mechanical parts, you are advised to send the gear motor out
for repairs to be performed by the technicians at the manufacturer.
It is absolutely forbidden to use the device for any other purposes. The installed control board (which
must have built-in electric friction), allows to select the following functions:
automatic: one control impulse will open or close the tilting gate;
semi-automatic: one control impulse will open or close the tilting gate.
In case of blackout, act on the manual unlocking device and move manually tilting gate. Remember
that this is an automatic device powered by electricity, consequently use with care. In particular,
remember:
- not to touch the device with wet hands and/or wet or bare feet;
- to turn off electricity before opening the control box and/or actuator;
- not to pull the lead to pull the plug out;
- to put the gate in movement only when it is completely visible;
- to keep out of the gate’s range of action if it is moving. Wait until it has stopped;
- not to let children or animals play near the gate;
- not to let children use the remote control or other operating devices;
- to carry out routine maintenance;
- in case of f ailure, to turn off electricity and operate tilting gate manually only if it is possible and
safe. Do not perform any intervention and call an authorized technician.
MAINTENANCE
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In accordance with the Regulation on Machinery, the following denitions are applicable:
− “Danger Zones:” any area inside and/or near a machine where the presence of a person is
a risk to his/her health and safety.
− “Exposed Person:” any person located entirely or partially in a danger zone.
A. Impact B. Crushing C. Conveyance
D. Cutting E. Slicing
A B C D E
TILTING GATES INSTALLATION GUIDE
IN ACCORDANCE WITH REGULATION 98/37/CE ON MACHINERY AND WITH REGULATION EN 12453 – EN 12445
Hazard areas of the tilting gate (figure 1)
LEGEND OF MECHANICAL RISKS CAUSED BY MOVEMENT
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MINIMUM LEVEL OF PROTECTION FOR THE MAIN EDGE
Mode of Use
Type of Activation Controls
Informed Users
(private area)
Informed Users
(public area)
Uninformed Users
Man-operated Command
□ Button command □ Turnkey button
command
The man-operated
command is not
allowed
Pulse command with visible doors
□ Power limitation
□ Detectors
□ Power limitation
□ Detectors
□ Power and photo
cell limitation
□ Detectors
Pulse command with non-visible
doors
□ Power limitation
□ Detectors
□ Power and photo
cell limitation
□ Detectors
□ Power and photo
cell limitation
□ Detectors
Automatic control (e.g. timed closing
control)
□ Power and photo-
cell limitation
□ Detectors
□ Power and photo-
cell limitation
□ Detectors
□ Power and photo-
cell limitation
□ Detectors
RISKS ANALYSIS AND SOLUTION SELECTION
IN ACCORDANCE WITH REGULATION 98/37/CE ON MACHINERY AND WITH REGULATIONS EN 12453 – EN 12445
MD
Annex
1
Types of Risks
Evaluation Criteria and Solutions to Adopt
(Check the box corresponding to the solution adopted)
Structural and wear-andtear mechanical risks
1.3.1
1.3.2
[1] Loss of stability
and parts falling off
□ Check the stability of this structure (columns, hinges, doors) compared with
the motor-generated stress.
Firmly fasten the motor using the proper materials.
□ If necessary, perform structural calculations in the appendix of the Technical
Documentation.
□ Check that the gate is equipped with antifall guard (independent and
redundant from the suspension system).
1.5.15
[2] Slipping
□ Check that eventual thresholds greater than 5 mm are visible, marked and
modelled.
1.3.7
Mechanical risks caused by the movement of the door (see references in figure 1)
1.3.8
1.4
□ WARNING – If the door/gate is used exclusively with the man-operated controls (and complies with the
requirements of regulation EN 12453) it is not necessary to protect the hazard points listed below.
□ WARNING – If the safety devices are installed (in accordance with regulation EN 23978) which prohibit
all contact between the moving door and people (e.g. photo-electric barriers, detectors), it is not
necessary to measure the actual operative stress.
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[3] Impact and crashing on the lower
retaining edge (figure 1, risk A)
□ Measure the closing stress (with the proper tool
required by regulation EN 12445) as indicated in
the figure.
Check that the values measured b y the
instrument are less than the ones indicated in
the graphic.
Take measurements at the following
points:
L = 200mm from the lateral edges and
half-way;
H = 50mm, 300mm,
and at maximum gate opening, minus
300mm (max 2500mm).
N.B. The measurements must be taken three
times at each point
In the graphic, the maximum values of the
dynamic operative, static and residual stresses
are indicated compared with the different
positions of the door.
□ If the stresses' values are higher, install a
safety device in accordance with the regulation
EN 12978 (e.g. safety edge) and take the
measurements again.
N.B. The reduction of the dynamic stress can
be obtained for example by reducing the door
speed or by using a sensitive edge with a high
elastic shear.
[4] Shearing on lateral boards (figure 1, risk B)
□ Measure the closing strengths in the points
shown in the figure.
N.B. The measurements must be taken three
times at each point
or
□ In case of a tilting gate installed in a private
residence, which does not face onto a public area,
and does not work with time automatic closing, it
is not compulsory to measure the force on the
lateral edges because the risk level is minimal. In
this case, the drive group must comply with the
norm’s requirements EN 60335-2-95.
Stress
400 N
Dynamic IMPACT
Stress
Static CRUSHING
Stress
150 N
25 N
0,75 s
5 s
time
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[5] Impact and crashing on the lower retaining
edge (gure 1, risk A)
Install two photo-cells (recommended height:
200 mm) to detect the presence of the test
parallelepiped (height 300 mm) positioned as
indicated in the gure.
In case of a tilting gate installed in a private
residence, which does not face onto a public area,
and does not work with time automatic closing,
the photocell is not compulsory.
To avoid the impact with trucks and jeeps that
park in the passageway, it is necessary to install
an additional couple of photocells at a height of
1000 mm.
N.B. The sample for detection is a parallelepiped
(700 x 300 x 200mm) having 3 sides with clear
and reective surfaces and 3 sides with dark and
opaque surfaces.
[6] Crashing, conveyance and cutting on the upper
retaining edge (gure 1, risk B)
Check that the height of the open space is > 2500
mm;
or
mount a safety device that complies with the EN
12978 norm (e.g. a sensitive edge);
or
in case of a tilting gate installed in a private residence,
which does not face onto a public area, and does not
work with time automatic closing, this device is not
compulsory.
[7] Lifting hazard
□ Check that the gate is not able to lift a weight of 20 kg
(or 40 kg in case of gates installed in private areas).
[8] Shearing on the motor’s lateral arms
(figure 1, risk D)
□ Check that the motor's and gate's arms do not form
shearing points among them, with the rigid coupling and
the door; or
□ Isolate and protect your hands from coming into
contact with the motor's and gate's arms; or
□ this protection is not compulsory in case of a tilting
gate installed in a private residence, which does not face
onto a public area, and does not work with time
automatic closing.
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MD
Annex
1
Types of Risks
Evaluation Criteria and Solutions to Adopt
(Check the box corresponding to the solution adopted)
[9] Impact, crashing,
cutting on the sliding
lateral guides of the
moving gate (figure 1,
risk E)
□ The sliding lateral guides (necessary for operating the system) must have a
minimum opening, so as not to allow the introduction of hands, which must not
come into contact with the gate's suspension systems (counterweights, strap
belts, cables, chains, etc...).
The sliding lateral guides must not have sharp edges.
N.B. Nonetheless the introduction of hands in the sliding guides can occur. It is
advised to affix the proper signs close to the sliding guides.
[10] Passage gate
inserted in the tilting
gate (figure 1, risk F)
□ Check that the movement of the tilting gate does not take place, should the
eventual passage gate contained in it not be closed completely.
[11] Conveyance,
trapping and cutting
due to the shape of the
moving door.
□ Eliminate and protect possible sharp edges, protruding parts, etc... (e.g. by
means of coverings or rubber profiles).
Electrical and electromagnetic compatibility
risks
1.5.1
1.5.2
[12] Lost Contacts
Electricity Detection
□ Use CE components and materials in accordance with the Regulation on
Low Tension (73/23/CEE).
□ Perform the electrical connections, the network connection, the ground
connections and relative checks, in compliance with the local norms and as
indicated in the installation manual of the activation group.
N.B. If the electrical power line is already connected (through socket and also
through cable box), compliance declarations with Italian Law 46/90 are not
compulsory.
1.5.10
1.5.11
[13] Risks of electromagnetic compatibility
□ Use CE components in compliance with the EMC Directive (89/336/CCE).
Perform the installation as indicated in the installation manual of the acti vation
group.
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MD
Annex
1
Types of Risks
Evaluation Criteria and Solutions to Adopt
(Check the box corresponding to the solution adopted)
1.2
[14] Safety conditions
in case of power
failure
□ Use activation groups in accordance with regulation EN 12453 and safety
devices in accordance with regulation EN 12978.
□ Verify that the gate does not perform dangerous movements (in case of
failure of the suspension system, the gate must not fall more than 300 mm).
1.5.3
[15] Energies different
from electrical power
□ If the hydraulic activation groups are used, they must comply with
regulation EN 982; or
□ If the pneumatic activation groups are used, they must comply with
regulation EN 983.
1.2.3
1.2.4
[16] Turning the
activation group on
and off
□ Check that the activation group resumes operations safely after a power
failure or shortage and that there are no hazardous situations.
[17] Power Switch
□ Install an omnipolar switch to electrically insulate the door/gate in
accordance with the applicable regulations. This switch must be positioned and
protected from involuntary or unauthorized activations.
1.2.5
[18] Control
Coherence
□ Install the controls (for example, the key selector) so that the user is not in a
dangerous area, and check that user understands the controls (for example,
the function selectors).
□ Use the CE radio controls in accordance with R&TTE Directive (1999/5/CE)
and in accordance with the frequency permitted by the law in each country.
1.5.14
[19] Trapping hazard
□ Install an unlocking device for the activation group that allows the door to be
opened and closed with a maximum effort of 225N (for doors/gates in
residential areas) or 390N (for doors/gates in industrial or commercial areas).
Supply the user with the tools and instructions needed to perform the unlocking
operations; check that the use of the unlocking device is user-friendly and does
not create additional risks.
1.2.4
[20] Emergency Stop
□ If necessary, install an emergency stop control in accordance with regulation
EN 418.
N.B. Make sure that the emergency stop does not create additional risks by
checking the operations of the safety devices present.
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MD
Annex
1
Types of Risks
Evaluation Criteria and Solutions to Adopt
(Check the box corresponding to the solution adopted)
Safety and Information
Integration Principles
1.7.1
[21] Notification Means
□ Install the blinker in a visible position to signal the movement of the door.
□ To regulate traffic vehicles, install traffic lights.
□ It is also possible to apply reflectors on the doors.
1.7.2
[22] Signs
□ Apply all necessary signs and warnings to draw attention to possible
unprotected residual risks and to warn about eventual, foreseeable, uses
that are non-compliant.
1.7.3
[23] Labellin
□ Apply the CE label or tag containing at least that indicated in the figure:
1.7.4
[24] Instructions for Use
□ Deliver the instructions for use, safety warnings and CE Compliance
Declaration to the user.
1.6.1
[25] Maintenance
□ A maintenance plan must be compiled and carried out.
Check the proper safety operations at least every 6 months.
□ Register eventual events in the Maintenance Record Book in accordance
with regulation EN 12635.
1.1.2
[26] Residual,
unprotected risks
□ Inform the user in writing (for example, in the instructions for use) of
possible residual, unprotected risks and foreseeable improper use.
Automatic Door
Producer (name – address):
Gate Type:
Identification Number:
Year of Construction:
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MAINTENANCE RECORD BOOK
This Maintenance Record Book contains technical
information as well as a list of installations, maintenance
and repairs performed and must be available for possible
inspections by authorized bodies.
TECHNICAL DATA AND INSTALLATION OF THE MOTORIZED DOOR/GATE
Customer:
_____________________________________________________________
Name, Address, Contact Person
Order Number:
_____________________________________________________________
Customer Order Number and Date
Model and Description:
_____________________________________________________________
Type of Door/Gate
Size and Weight:
_____________________________________________________________
Size of the Passage, Size and Weight of the Door
Serial Number:
_____________________________________________________________
Unique Identication Number of the Door/Gate
Location:
_____________________________________________________________
Installation Address
LIST OF COMPONENTS INSTALLED
Motor/Activation
Group:
_____________________________________________________________
Model, Type, Serial Number
Electrical Panel:
_____________________________________________________________
Model, Type, Serial Number
Photo-cells:
_____________________________________________________________
Model, Type, Serial Number
Safety Devices:
_____________________________________________________________
Model, Type, Serial Number
Control Devices:
_____________________________________________________________
Model, Type, Serial Number
Radio Devices:
_____________________________________________________________
Model, Type, Serial Number
Blinker:
_____________________________________________________________
Model, Type, Serial Number
Other:
_____________________________________________________________
Model, Type, Serial Number
Technical Assistance:
(Name, address, telephone)
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LIST OF RESIDUAL RISKS AND IMPROPER, FORESEEABLE USE
Notication through signs posted on the product’s danger points and/or through written notices to deliver to and
explain to the user or the person in charge about the existing risks and the improper, foreseeable use.
_____________________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________
MAINTENANCE RECORD BOOK
Description of the Intervention
(Check the box corresponding to the intervention carried out. Describe possible residual risks and/or improper, foreseeable use)
□ Installation □ Start-up □ Adjustments □ Maintenance □ Repairs □ Changes
Date: ___________ Signature of the Technician: _________________ Signature of the Customer: ___________
Description of the Intervention
(Check the box corresponding to the intervention carried out. Describe possible residual risks and/or improper, foreseeable use)
□ Installation □ Start-up □ Adjustments □ Maintenance □ Repairs □ Changes
Date: ___________ Signature of the Technician: _________________ Signature of the Customer: ___________
Description of the Intervention
(Check the box corresponding to the intervention carried out. Describe possible residual risks and/or improper, foreseeable use)
□ Installation □ Start-up □ Adjustments □ Maintenance □ Repairs □ Changes
Date: ___________ Signature of the Technician: _________________ Signature of the Customer: ___________
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DECLARATION OF CONFORMITY
(OF THE MANUFACTURER)
Manufacturer: QUIKO ITALY SAS
hereby declares, under his liability, that the products:
QK-B220, QK-B24
are in compliance with the essential safety requirements of the regulations:
Electromagnetic Compatibility Directive .........................2004/108/EC
Low Voltage Directive ...................................................... 2006/95/EC
Machinery Directive .........................................................2006/42/EC
and their amendments and modifications, and with the regulations set forth by the
National Legislative Body of the country in which the machinery is destined for use.
Via Seccalegno, 19
36040 Sossano (VI)
Italia
Managing Director
Luca Borinato
Sossano, 19/10/2011
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DECLARATION OF CONFORMITY
(OF THE INSTALLER)
The undersigned:
Address:
in charge of the set-up, declares that the product:
Gate type:
Location:
are in compliance with the essential safety requirements of the regulations:
Electro magnetic Compatibility Directive .........................2004/108/EC
Low Voltage Directive ............................................................2006/95/EC
Machinery Directive ................................................................2006/42/EC
and also declares that the related and/or specific national technical regulations have been
followed:
EN 12453/EN 12445 on Industrial, Commercial and Residential Gates and Doors – Safe
Use of Motorized Doors – Requirements and Classification – Test Methods;
EN 12604/ EN 12605 on Industrial, Commercial and Residential Gates and Doors –
Mechanical Aspects – Requirements and Classification – Test Methods;
CEI 64/8 Electrical Systems Using Nominal Tension Not Higher Than 1000V a.c. and 1500
V d.c.;
EN 13241-1 (Industrial, commercial and garage doors and gates), conformity evaluation
(6.3).
Notes:
Place and date: ………………………………………
20
The Manufacturer can technically improve
the quality of its products without
any prior notice.
QUIKO ITALY
Via Seccalegno, 19
36040 Sossano (VI) - Italy
Tel. +39 0444 785513
Fax +39 0444 782371
info@quiko.biz
www.quikoitaly.com
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