BATOR AFFD238 BATOR AFFD400 · 2020. 3. 15. · BATOR AFFD400 . 090919-100-2 Opening must be , and...

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090919-100-1 INSTALLATION INSTRUCTIONS FOR BATOR AFFD238 BATOR AFFD400

Transcript of BATOR AFFD238 BATOR AFFD400 · 2020. 3. 15. · BATOR AFFD400 . 090919-100-2 Opening must be , and...

  • 090919-100-1

    INSTALLATION

    INSTRUCTIONS

    FOR

    BATOR AFFD238

    BATOR AFFD400

  • 090919-100-2

    Opening must be , and to ensure proper installation. These

    instructions proceed on that basis.

    Figure #1

    1. Prepare the opening according to the illustration

    2. Center opening. Mark a Plumb Line on each jamb at dimension

  • 090919-100-3

    Figure #2

    3. Make a Level Line accross the header and jambs. Refer to this line to check for level.

    4. Attach the upper track withthe anchor bolts according to figure #2.

    5. Begin with the left or right jamb. Screw the vertical jambs to the already installed

    upper track by using the corresponding screws. : Loosely fix the jamb with 3-

    4 anchor bolts.

    6. Before installing the track, measure the distance from the (step #2) to the vertical track already in place. Locate the top of the other track at the same height with reference to the Level Line. (figure #3 and figure #4). Ensure all edges (upper track vs. jambs; jambs vs. finished floor) are in perfect 90°.

  • 090919-100-4

    Figure #3

    Figure #4

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    1. Prepare the pins at the hinges as shown on Figure #1 and #2.

    Figure #1

    Figure #2

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    Use the corresponding grub screw (part-no. 103392) to temporary hold the pins in position.

    2. Add the thrust bearings (part-no. 101168) on the corresponding pins.

    3. The top panel in the crate is labeled “A”. Attach a lifting belt to get the panel as shown in Figure #3). The belt must be well dimensioned to maintain the weight of one panel. Use a crane, fork lift, boom lift or any other adequate lifting device to maneuver the door panel. Lift panel “A” in vertical position above the hinges. ATTENTION: The gap between the upper track and the upper hinge is very limited. Lower the panel when its position is right above the top and bottom pin.

    Figure #3

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    Figure #4

    4. Release the grub screw slightly and push it up in its final position. Reuse the grub screw to fix the pin in its final position. ATTENTION: The grub screw has to meet the notch to ensure perfect position as shown on Figure 5.

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    Figure #5

    5. Repeat Step 1-4 for panel “D”

    WARNING! USE ALWAYS WOODEN WEDGES TO CONTROL THE POSITION OF THE PANELS, ESPECIALLY ON WINDY DAYS.

    6. Insert and fix pins and thrust bearings on the free hinges at panel “A” & “D”.

    7. Repeat point 3 + 4 for panel “B” & “C”. At this point, all 4 panels are hinged and hanging loose in the posts

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    8. Insert the “A”-shaped rubber block on top of the center panel “B” and “C”. These rubber blocks keep a distance between the panels of about 2” and avoid damaging the panels when fully open the door.

    9. Slide from the side4 the two chariots (part-no. 101357 [left] and part-no. 101356 [right] according Figure 6 in position,

    10. Insert the large pins (part-no. 101305) from below of the top hinge of the door meeting the trolley. On top of the trolley add a washer and the top screw. Use two (2) M10 keys: Hold the M10 screw at the bottom while screwing at the top. By fixing the top screw the corresponding panel get lifted slightly. ATTENTION: protect the door to avoid any damage on the surface.

    11. Fix the pin with the grub screw (part-no. 103370 and 103418 [nut]) as shown in Figure #6

    Figure #66

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    12. Fix the bottom rollers at the center panels “B” & “C” with the corresponding screw set (part-no. 101143 [bottom rollers], 103621 [3 screws]) as shown in Figure #7.

    Figure #76

    13. Install the aluminum handle-sets (part-no. 101098, 103252 [screws]) at man’s height (4'-6 1/4") according to the

    Figure #8

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    14. When door is fully closed, check the height of the panel “B” & “C”. For proper functioning of the door, both lower edges must positioned at the same height. If this is not the case, shift slightly shim the corresponding jamb to take the center panels to the same height.

    15. Once the door is well levelled, fix the jambs with the residual anchors. (see loose installation of the jambs (see also section INSTRUCTION 100 – Step #5)

    16. Set all the grease fittings. ATTENTION: For the hinges flat grease fittings (part-no. 103377 [regular grease fittings for panel b + c], 103913 [flat grease fittings for panel a+d)) as shown in Figure #9 to be used.

    Figure #9

    17. When all grease fittings are set, use a grease press to lubricate all hinges.

    18. Close the top of the hinges with plastic caps to keep dirt and dust out.

    19. Close the door completely. Check position of the center receiver at finished floor on interior and exterior side (part-no 101496 [plates]; according Figure #10). Use anchor bolts (part-no. 101613 + 103629 [anchor bolt and corresponding screw]) for fixing it on the finished floor.

  • 090919-200-8

    Figure #10

    20. Install the brushes (part-no. 104453 [brush], 103493 [self-tapping screw]) according with the provided self-tapping as shown on Figure #11.

    Figure #11

    21. Remove the ruber holder on all rubber profiles as shown in Figure #12 and Figure #13. These “holder” are to be removed after the installation of the panels. Removing the “holders” is required for proper functioning of the safety edge.

  • 090919-200-9

    Figure #12 AND Figure #13

    22. In case the rubber seal on top of the upper track is not set, attach the rubber seal (part-no. 101023) on the upper C-shape track as shown in Figure #14 and Figure #15.

    Figure #14 AND Figure #15

  • 090919-300-1

    1. Use for this task a stable platform to work on.

    2. Lift drive system and gearbox to the foreseen consoles and fix it loosely as shown in Figure #1 and Figure #2. Before fixing the drive system, make sure the roller of the arm is positioned properly in the “U”-profile at the top of the panel “A” and “D”. IMPORTANT: Depending on the situation, the motor and gearbox may be installed on the opposite side than shown in this document. Check the position of the boxes on the shop drawings attached to the door.

    Figure #1

    3. Close the door slowly and push tight against the door to simulate the closing position. Keep pushing it while installing the transmission shaft. Use the supplied chains couplings as shown in Figure #4 on both sides of the transmission shaft.

    4. Open slowly the door to see if the coupling of both sides of the door is working properly.

  • 090919-300-2

    Figure #2

    Figure #3

  • 090919-300-3

    Figure #4

    Figure #5

  • 090919-300-4

    5. Attach the dis-engager cable as shown on Figure #6.

    Figure #6

    6. Verfiy the position of the disengager handle. ATTENTION: KEEP ALWAYS A LOOP OF APPROXIMATELY 2 FT. DIAMETER ON TOP OF THE DOOR (SEE FIGURE #6). A SMALLER DIAMETER MAY JAM THE THREAD INSIDE THE CABLE!. Set the handle (part-no. 102137 [handle], 101552 [fixing angle], 104581 [screws], 104418 [washer]) accordingly by using the corresponding fixing screws (part-no. 101613 [anchor], 103628 [screws], 103385 [washer]).

    7. Dis-engage the motor from the gear box with the help of the handle.

    8. Push the door in fully close position. Open the lid at the gear box (w/the motor attached) to get to the end switch. Push the door tight in close position, turn the transmission shaft in the same direction and check the position of “Banana” in the gear box At this point, the end-switch must be activated. If required, the Banana must be released, displaced slightly and fasten in its final position as shown in Figure #7.

  • 090919-300-5

    Figure #7

    9. Once the banana is properly set, close the motor lid.

  • 090919-400-1

    1. Attach the control unit in the proximity to the door as shown in Figure #1.

    Figure #1

    2. Install the control button station “Open-Stop-Close” in the proximity of the door according to Figure #1 (part-no. 102842 [box], 101610 [nylon anchor], 103268 [screws]). Run a cable conduit to the control unit.

    3. As a standard, one (1) photo eye is foreseen per door. IMPORTANT: This may vary depending on the local requirements. Install the photo eye according to Figure #5.

    4. Install two (2) junction boxes on the wall on each side of the door for receiving the cables of the safety strip and the photo eye(s).

    5. On top of panel “B” and “C” a pre-installed junction box is available. Run the cables from this junction box to the junction boxs installed at left and right hand side of the door.

  • 090919-400-2

    6. Install the photo eye (sender / receiver) according to Figure #5 and Figure #6.

    7. Run the cables in the frame profiles up to the junction boxes.

    8. Run the cables from both junction boxes to the control unit. Use adequate cable conduits (not included).

    9. Attach the cables for the motor, motor break, and limit switches as shown in Figure #2 and Figure #3 and run it directly to the control unit in a separate conduit. IMPORTANT: Use a separate cable conduit to avoid possible interferences!

    Figure #2

    Figure #33

    10. Run feeding power to the control unit in a separate conduit.

  • 090919-400-3

    11. Attach all the cables of push button station(s), safety edges, photo eye, feeding power and other optional safety components according to Figure #4 and separate electrical diagram.

    Figure #4

    Figure #5

  • 090919-400-4

    Figure #6

    12. Attach optional EMERGENCY push button to control unit as shown in Figure #7

    Figure #77

  • 090919-400-5

    13. Attach optional Radio receiver to control unit as shown in Figure #8

    Figure #8

    14. Attach optional potential-free contact for flash light to control unit as shown in Figure #9

    Figure #9

  • 090919-400-6

    15. Attach optional traffic lights to control unit as shown in Figure #10

    Figure #10

    16. Attach optional inductive loop to control unit as shown in Figure #11

    Figure #11

    17. ATTENTION: BEFORE TURNING ON THE CONTROL UNIT, CLEAR THE PATH OF THE DOOR TRAVEL. REMOVE ANY OBSTACLES BEFORE LAUCHING THE CONTROL UNIT! At the control unit, switch the selector to “manual” and turn the main switch to “ON”. The background color of the screen at the control unit should be green.

  • 090919-400-7

    18. Check LED lights of the PLC and power supply in door closed position as shown in Figure #12. Before continuing ensure that the control unit shows the same signals as in Figure #12.

    Figure #12

    19. Open the door by pushing the “OPEN” button (when door is in semi open or open position); close the door by pushing the “CLOSE” button (when door is in closed position). In case of a failure push the “STOP” button. In case of emergency switch off completely the control unit on the main power switch.. See Section INSTRUCTION 500 for modifying factory settings and troubleshooting.

  • 090919-500-1

    The standard background color of the screen at our control unit indicates following states:

    Green = No errors identified

    Red = Ouch! Something went wrong. Before continuing using the door, the

    error state has to be confirmed and a reset at the control unit has to be

    performed. Press [F1] button to reset the control unit.

    Blue = The control unit screen shows either statistical values or is in a program

    that allows the modification of the parameters.

    ATTENTION: Do not attempt to alter any factory settings. Please contact BATOR or RAYNOR for assistance at 1-888-472-9667.

  • 090919-500-2

    The screen landscape is presented as shown in Figure #1.

    Use the arrow keys at the screen panel to switch between the different screens:

    State of the door Statistical values Real-time values (position and mode) (counting movements) (resistance etc.)

    §

    (continued on following page)

    ----------------

    Door closed

    End position

    ---- MANUAL ----

    ----------------

    Door closed

    End position

    ---- MANUAL ----

    *OPER. RECORDS:*

    Drive Runtime:

    0 h 5 m

    Openings total:

    5

    Closing total:

    6

    Rev Light Barr.:

    2

    Rev Main C.Edge:

    0

    Rev. SafetyEdge:

    0

    Stp Safety Chain:

    0

    *** SERVICE: ***

    Version 1.200

    Date 20181126

    Language EN

    Main ClosingEdge

    Input: 8105 mV

    Resist: 4071 Ohm

    State: ON

    Safety Edge

    Input: 0 mV

    Resist: 0 Ohm

    State: EXT

  • 090919-500-3

    Figure #1

    Timeouts Open:

    2

    Timeouts Close:

    1

    TestF LightBarr:

    0

    TestF. MainEdge:

    0

    TestF. SafeEdge:

    0

    SignErr End Sw.:

    4

    SignErr MainEdge

    11

    SignErr SafeEdge

    0

    Errors Freq.Conv

    1

  • 090919-500-4

    When pressing simultaneously [F4] and [F6] at the screen, following edit screens appear:

    Use the [] button to maneuver the cursor to the menu “Variables”.

    Press the [OK] button to get into the the selection list. Following screen appears:

    By using the cursor keys, a function can be selected. Then press the [OK] button to check the value of the variable:

    The Radio Function parameter (Funct_Radio) is currently set on 0. If the value shall be altered, press [OK], otherwise use the key [ESC] to return to the previous screen. When pressing [OK], the following screen appears:

    RUN

    00:03SAT

    Mode Switch

    Variables

    I/O Status

    Geben Sie hier eine Formel ein.

    RUN

    00:03SAT

    Mode Switch

    Variables

    I/O Status

    Geben Sie hier eine Formel ein.

    [Variable List]

    Drive_Type

    EmergClose_On

    EmergOpen_On

    Function_I06

    Function_O01

    Funct_Radio

    Mode_TrafSign

    Funct_Radio:

    BOOL

    0

  • 090919-500-5

    A cursor below the value appears. With the [] and [] a new value can be set. When set the value press [OK], then [ESC]. Following screen appears:

    Press [OK] to save the modification. Press several the [ESC] button to return to the main screen.

    Description and values of each parameter are shown in Figure #2.

    Funct_Radio:

    BOOL

    0

    Save variable entry!

    [ESC] [OK]

  • 090919-500-6

    Figure #2

    Parameter DescriptionFactory

    settingConfiguration Parameter

    UNI HEX

    Drive_Type Door drive type 0 0 electric drive (contractor or FC)

    1 pneumatic drive (valves)

    Emerg_CloseOn Activate Emergency door closing 0 function lock

    constant contact drive 1 function unlock

    Emerg_OpenOn Activate Emergency door opnening 0 function lock

    constant contact drive 1 function unlock

    Function_I06 Function of input I06 0 0 Stop Door, opener (NC)

    1 Safety chain, opener (NC)

    Function_O01 Function of output O01 001 000 Pulse at the beginning run ( »light)

    001 On, drive on / drive to ( »signalisation / light)

    002 On, drive on / drive to or OPENED ( »Lüftung)

    003 Disorder

    Mode_TrafSign Traffic light settings 0 No function

    1 No function

    opened door green continuous light 2 closed: red continuous light; move: red flashlight

    opened door green continuous light 3 closed: red continuous light; move: red continuous light

    opened door green continuous light 4 closed: dark; move: red flashlight;

    opened door green continuous light 5 closed: dark; move: red continuous light

    Sel_DRevTime Select Drive Reversing Time 0 0 Short reversing time (FC control, ca. 20ms)

    1 Long reversing time (contractor control, ca. 500ms)

    Sel_InputCLaP Selection Input Modul 1 I00 0 0 Passing closure (inductive loop)

    1 Passing closure (light barrier, safety eye)

    Set_ModeMCE Set mode/type of main closing edge 000 000 Direct evaluation analogical input

    85 External evaluation, Digitalsignal (NC)

    Set_ModeSE Set mode/type of side edge 90 000 Direct evaluation analogical input

    90 External evaluation, Digitalsignal (NC)

    Sys_Command System command (single exeution) 000 No function

    202 CA Clear All / clear operating data

    245 F5 Factory Settings / Control to factory setting

    Time_CpBrkCL Pulse time counter pres. brake close 500 [ms] Pulse time counter pressure brake close

    Time_CpBrkOP Pulse time counter pres. brake open 500 [ms] Pulse time counter pressure brake open

    Time_DlyBrake Time brake reaction 300 [ms] Time protection engine brake

    Time_DlyCLaP

    Delay time closing, after release of the

    light barrier or loop 5000 [ms]Time delay, induction close after pass

    Time_DlyDrive Time delay drive on after cmd 20 [ms] Time delay, offset door movement

    Time_DoorOpen Time door held open 15000 [ms] Time door held open, automatic

    Time_MaxClose Maximum time for travel close 30000 [ms] Observation, drive running time close

    Time_MaxOpen Maximum time for travel open 30000 [ms] Observation, drive tunning time open

    Time_RecCLaP Recognition time close after pass. Minimal

    time of the light barriers or loop activity

    for active PASS Auto-Close 2500 [ms]

    Time delay, Recognition close after pass

    Time_RelfEdge Time drive reversing after side edge 3000 [ms] Running time, discharge secondary edge

    Time_RspLiBar Time response light barrier off 0 [ms] Time delay, Signal Barrier electric eye

    Code

  • 090919-500-7

    The opening and closing speed of the door is set on the frequency converter:

    A set of various parameters can be set / altered. A detailed description can be found in each control unit.

    WARNING

    Mortal danger from fire, electric shock!

    Death or serious injury!

    Always use the frequency converter as intended.

    Do not modify the frequency converter.

    Only use spare parts and accessories sold or recommended by the

    manufacturer.

    During assembly, ensure adequate distance to adjacent components.

    Due to the risk of injury, the parameters should not be altered without permission and previous consulting BATOR (+41 62 956 12 12) or RAYNOR (1-888-472-9667).

    For changing opening speed, the parameter P105 (overall maximum frequency) and A411 (effective opening speed) need to be altered. The higher the value, the faster the door moves.

  • 090919-500-8

    ATTENTION: any alteration of the factory setting may increase the speed of the door. Changing opening / closing speed of the door may stay in contrast to local safety regulations. BATOR cannot held responsible for any modification in the programming.

    Parameter Description Factory Setting Comment

    P101 Motor rated voltage 230V According to type plate of motor (V)

    P102 Motor rated frequency

    60 Hz According to type plate motor (Hz)

    P103 Level electornic motor protection

    0.8 A Set to rated motor current according to type plate (A)

    P105 Maximum frequency

    60.00 (Hz) Maximum possible frequency

    P106 Start source 2

    P108 Target speed 4

    P109+A401 Acceleration time 1 2.0 s Open / close of the approached ramp

    P110+A402 Delay time 1 0.6 s Breaking ramp

    A410 Fixed speed 0 10.00 Frequency creep speed

    A411 Fixed speed 1 (opening)

    60.00 Frequency open

    A412 Fixed speed 2 (closing)

    40.00 Frequency close

    A446 Clock speed 4.0 kHz Increase value when motor “whistles”

    A461 Motor rated current

    0.8 A Set to rated motor current according to type plate (A)

    t221 Function selection relay output R1/R2

    0 When setting brake control via relay / value 2

  • 090919-500-9

    Parameter Description Factory Setting Comment

    d001 Monitoring output frequency

    Shows frequency in Hz

    d003 Monitoring output current

    Shows output current in A

    d004 Monitoring output voltage

    Shows output voltage in VAC

    d007 Code error Indicates the last fault

    The User Manual of the PowerFlex 4M frequency converter is available in each of the control unit boxes.

    Contact BATOR Industrial Doors Ltd. Hofmattstrasse 14 CH-3360 Herzogenbuchsee web: www.bator.com mail: [email protected] phone. +41 62 956 12 12

  • 090919-600-1

    INSTRUCTION 600 PARTS LIST

    Part Part-# Description Qty.

    101443 Bottom roller installed at the center of the door

    2

    101496 Center Receiver installed at the finished floor at the center of the door

    4

    103377 Grease Fitting for door panel “B” and “C”

    6

    103474 Spring Washer 6

    103621 Socket Head Screw (M8x14)

    6

    103913 Grease Fitting for door panel “A” and “D”

    4

  • 090919-600-2

    Part Part-# Description Qty.

    104453 Nylon Brush in different lenghts (side and front)

    6

    103493 Self Tapping Screw (Marutex 4,8 x 19)

    24

    101612 Screw anchor (M10 x 55) 10

    103566 Screw (M10 x 40) 32

    103391 Washer M10 32

    101632 Plastic Cap 26

    No picture available

    101592 Spacer plate 10

    103625 Screw (M8 x 25) 4

  • 090919-600-3

    Part Part-# Description Qty.

    103385 Washer M8 4

    No picture available

    103600 Socket Head Screw (M5 x 12)

    4

    No picture available

    103486 Spring Washer B5 4

    100395 Cable Conduit incl. Lid 1

    103268 Screw 4 x 30 12

    103396 Washer M5 9

    101610 Nylon Dowel (Dia 3.5 – 5) L=30

    13

    102137 Handle for Releasing Drive 1

    104581 Socket Head Screw (M6 x 35)

    2

  • 090919-600-4

    Part Part-# Description Qty.

    101552 Wall mounting Bracket (Handle)

    1

    101613 Scew anchor (M8 x 45) w/ internal thread

    6

    103628 Socket Head Screw (M8 x 35)

    2

    103385 Washer M8 2

    101356 Carriage right 1

    101357 Carriage left 1

    101305 Pin (Diam. 30) w/ Washer 2

  • 090919-600-5

    Part Part-# Description Qty.

    101257 Pin (Diam. 25) 8

    101168 Thrust Bearing (Diam. 25) 8

    103392 Grub Screw w/ Point 12

    103418 Nut (hexagonal, M8x0.5) 8

    101539 Bumper “A”-Shape Rubber Profile

    2

    101924 Junction Box 2

    103443 Slotted Pan Head Screw (3.5 x 22)

    6

  • 090919-600-6

    Part Part-# Description Qty.

    101098 Door Handle, aluminum 2

    103252 Countersunk Screw (4.8 x 22)

    8

    No picture available

    103065 Opening Limiter 1

    102182 Chain Coupling 2

    102159 Chain Coupling Chassis 2

  • 090919-600-7

    103301 Feather Key 8/7 – 40 2

    103291 Feather Key 6/6 – 36 2

    102842 Push Button Pad (Open-Stop-Close)

    1

    102734 Safety Eye (sender) 1

    102731 Safety Eye (receiver) 1

    102657 Front Plate 35/85/2 Aluminum for Safety Eye

    2

    103438 Countersunk Screw (3.5 x 9.5)

    4

  • 090919-600-8

    Part Part-# Description Qty.

    103057 Cable UL U72x0.75 PVC 62 ft.

    No picture available

    101670 BATOR Plate 15x45x0.5 Aluminum

    2

    102174 Drive System (right) 1

    104418 Washer 4

    100842 Sealing tape (between upper track and wall)

    60 ft.

    102185 Gearbox (drive system) 1

    101945 Wire protecting sleeve 4

  • 090919-700-1

    Troubleshooting shall be performed by factory authorized personnel only. Service

    and/or installation by unauthorized personal can void warranty.

    Motor fails to run or

    control circuit fails to

    energize

    Fuses blown or circuit

    breaker “tripped”

    Check fuses or circuit

    breaker box

    Operators are protected

    from running in overload

    conditions by thermal

    overload devices of the

    automatic reset type

    Consult distributor

    If contacts for motor

    controller energize but

    motor still fails to operate

    Consult distributor

    Push buttons energize on

    only one side of the control

    contacts

    Check all electrical

    connections for broken or

    loose wires, etc. Check

    electrical connections for

    any optional equipment:

    Photo cell, safety edge or

    interlocks

    Door is not fully open or

    close

    End Switches need to be

    adjusted

    Adjust de end switches in

    the gear box.

    Consult the distributor

    Door opens but does not

    close

    Before closing process the

    control unit is verifying the

    entire safety chain (photo

    cell, radar, main safety edges

    etc.). If one of the

    components is broken or

    does not respond to the

    checking signal, the door

    won’t close

    Verify all safety

    components. If the defect

    cannot be detected,

    consult the distributor.

  • 090919-700-2

    Problem Cause Correction

    Safety edge is not

    working

    Open circuit on door

    mounted switch. Insert

    continuity checker. If

    compressing safety edge

    does not close circuit, the

    problem is a faulty edge.

    Defective contact stripe

    must be replaced.

    If a wireless system is used,

    the battery power of the

    sender may be down.

    Check battery for proper

    charge. If necessary,

    replace the battery.

    Photo cell is not working No power supply available

    for sender and/or receiver

    Check for cause starting

    with the fuse in the control

    panel. Use a volt-meter to

    verify 24VDC.

    Sender and/or receiver out

    of alignment

    Loosen attachment bolts

    and align both units. Verify

    that the cable is not

    defective.

  • 090919-800-1

    Dear Client,

    Thank you for your confidence in our doors.

    Since more than 65 years BATOR GROUP develops, produces and installs various types

    of doors and provides service and maintenance.

    For BATOR after-sales service is very crucial. With the handover of this Service and

    Maintenance Manual of your door we guarantee the availability of replacement parts

    for all parts during the life-span of your door.

    In addition, BATOR guarantees an optimum of customer value through a permanent

    advancement and innovation cycle.

    BATOR disposes over a tight network of service points and corresponding specialists

    for repair and maintenance work.

    With modern warehouses BATOR provides world-wide components from the main

    factory or service point within few hours.

    Our high-quality industrial doors remain operative under severe service and weather

    conditions and ensure at any time a vast operator safety and ease of use.

    The door system is a technical equipment and requires a periodic maintenance

    executed by a specialist – especially the safety elements for guarantee operation safety.

    We are pleased to provide you a service and maintenance offer.

    Maximize our ISO 9001 service level!

  • 090919-800-2

    Before performing anytime work on any part of the door, always lockout the door using

    the electrical disconnect on the control panel door and follow proper lockout

    procedures. Failure to do so can result in serious injury or death.

    Even though your BATOR Four-Fold Door is equipped with various safety features to

    prevent personal injury or damage to the door, it is recommended not to stand in the

    door path.

    The instruction manual composed to simplify the maintenance of your BATOR Four-Fold

    Door.

    The limits in the gear box are preset and should be placed in optimum position.

    Nevertheless, in certain situations, an adjustment is required. When setting the limits

    for the first time, move door with extreme caution and set the limits so as not to overrun

    the door past the full open and full close positions.

    Standard safety procedures shall be followed, the manual is designed for accredited

    and factory trained installers working in the door industry and the familiar with the

    standard installation and operating procedures. It is assumed that construction

    procedures accepted in the industry will be followed in the areas not detailed and for

    general safety precautions. If any questions should arise on your particular installation,

    please feel free to call BATOR North America LLC (US and Canada) or BATOR Industrial

    Doors Ltd. (Switzerland) and ask for technical service.

    Each BATOR four-fold door system consists of opening frame, (4) four sections (two

    jam and two leading sections) fully glazed with insulated and laminated glass sheets,

    hardware, operating mechanism, weathering, electric operators, and control units.

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    1 Upper track 7 Operating handle (optional) 13 Emergency release

    2 Lower track (optional) 8 Wicked door (optional) 14 End-switch of lock bar

    3 Door element 9 Door handle (optional) 15 Flexible conduit

    4 Carriage 10 Reed contact wicked door (opt.) 16 Main safety edge (contact strip)

    5 Hinge 11 Door closer (optional) 17 Contact mat (optional)

    6 Door fastener 12 Motor system 18 Light barrier (electric eye

    The opening frame is manufactured from hollow structural steel tubes, bolted type

    construction, all cavities filled with mineral wool insulation. Jamb hinges to support the

    door sections are welded to the jambs. The horizontal top track is attached with

    counter-sunk screws to steel or concrete wall. The whole opening frame assembly is

    screwed to the building columns and lintel.

    12 13 11 1 10 4 15 14

    5 3 8 9 6 7 2

    16

    17

    18

    2 Bodenführungsschiene3 Torflügel4 Laufwagen5 Scharnier

    8 Schlupftüre ( Servicetüre ) 9 Einsteckfallenschloss-Türdrücker10 Sperrschalter Schlupftüre11 Türschliesser

    16

    1 Obere Führungsschiene

    6 Torverschluss

    7 Bedienungsgriff

    12 Torantrieb

    13 Notentriegelung14 Endschalter Schlosstange15 Flexible Leitung16 Hauptschliesskante17 Kontaktteppich18 Lichtschranke

  • 090919-800-4

    There are (4) four sections per opening, two sections folding each side. The sections

    frames are manufactured from hollow special BATOR structural steel tubes. Each door

    panel is fully glazed and on both sides wet silicone sealed. The aluminum holding bead

    on the interior side is clipped.

    Each side (set of two sections) are supported with (2) two hinges welded to the frame

    jambs, the jab hinges are incorporated with needle and thrust bearings.

    The operating mechanism consist of two rotating arms, a motor on either left or right

    hand side, two gear boxes which are connected by a transmitter shaft. A disengage

    handle at man’s height is attached on the side where the motor is located.

    The is (1) one electric operator (motor) for each opening; the operator is located either

    on top of the left or right top corner of the door. The operator consists of an electric

    brake; the motor coupled to a double-reduction gear reducer, and limit switches (door

    open / door closed). The operator is mounted on a steel structure welded on the top

    track of the door. The power of the drive is transmitted to the gear boxes, which are

    connected by a transmitter shaft. The outer door panels (A) and (D) are connected to

    the arms attached to the gear boxes. The top trolleys mounted at the two center panels

    (B) and (C) are guided for full travel by the top guides mounted at the lintel level.

    The operator is controlled by wall mountable NEMA 4 approved enclosure housing

    programmable logic controller with LED indicators, various timer for e.g. close,

    monitoring function for photo cell, receiver, cycle counter, fuses and exterior screen.

    Programmable logic control

    A =

    Lockable in position “OFF” with a padlock

    In case of interruption turn the main switch (A) in

    “OFF” position. Wait 10 seconds and turn the main

    switch (A) to “ON” position. The interruption gets

    acknowledged by sending a “OPEN” impulse (e.g.

    open button at the button pad.

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    Leading edge of each leading door section is equipped with contact edges, which are

    activated in closing motion. In case the door hits an object during the closing cycle, door

    reverses immediately.

    A set of recessed through-beam photo cells to NEMA 4 is provided to prevent the door

    closing in case its beam is broken. Optionally, the through-beam photo cell can be

    activated for the “passing close” function.

    Optional. an intermittent audible alarm can be provided to sound before and during the

    closing movement until door stops, when CLOSE button is pressed.

    RED and/or GREEN Traffic lights are provided on the exterior and interior of the

    building.

    The door is provided with bonding straps to ground the doors electrically.

    The entire door is entirely sealed by EPDM rubber profiles: between the panels,

    between panel and jamb and between finished floor and panels). Additionally, at the

    bottom nylon brushes with integrated rubber seal are provided for interior or exterior

    installation. An integrated dove tail in all steel profiles is holding the corresponding

    rubber profile. This allows an easy rubber profile replacement whenever required.

    On the finished floor at the center of the opening a guide support keeps the door in

    perfect position.

    An integrated program limits the running time of the motor, which protects the motor

    in case of a unexpected blockage or defective end switch. The control unit falls into

    “ERROR” mode and switches off the motor. For reset, the control unit has to be

    switched “OFF” and after 10 seconds to be switched back “ON”.

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    The electric operator are mounted on the jamb tubes, are designed to move the jamb

    sections under controlled speed. Power from the operator shaft is transmitted to the

    jamb sections through linkages. In case of power failure, the doors can be moved by

    disengaging the motor. The door can subsequently be manually opened. After manual

    operation, the door can be reengaged at any position by using the handle at man’s

    height. The incorporated frequency converter is designed in a manner that the door will

    begin to move slowly and accelerate to full speed and will slowly decelerate before

    stopping at the end of the travel.

    Two limit switches are located in the gear box directly attached to the motor.

    The push buttons are located at the proximity of the door at man’s height. At the control

    unit there is a switch where two different modes can be set: “MANUAL” or

    “AUTOMATIC”. Depending of the position the door acts differently:

    If the switch of the control unit is set to “MANUAL”, pressing the “OPEN” button opens

    the door and does not close automatically. In order to close the door the “CLOSE” button

    needs to be pressed for a moment.

    If the switch of the control unit is set to “AUTOMATIC”, pressing the “OPEN” button

    opens the door and keeps the door open for a set time (can be altered). Once the door

    reaches its open position, the countdown starts. After the time elapsed the door

    automatically closes. If an obstacle is cutting the through-beam photo cell, the door

    remains open; otherwise it closes the door.

    Make sure that door path is clear of any obstructions.

    Press the “OPEN” button, the door will begin to open. Release the “OPEN” button and

    the door opens automatically until it reaches the full open position.

    Considering the door is set to “AUTOMATIC” mode, a timer starts counting back the

    pre-set time. This time can be altered (changing the corresponding parameters). Before

    the door automatically closes, the system checks if the safety edges and the through-

  • 090919-800-7

    beam photo cell is working properly. If this is the case, and the through-beam photo cell

    is not broken, e.g. by and obstacle, the door automatically closes until it reaches its full

    close position.

    In case the door is set to “MANUAL” mode, the CLOSE button needs to be pressed.

    Similar as in the “AUTOMATIC” mode, the door checks first the safety chain. If all safety

    devices are working properly, the door starts closing until it reaches its full close

    position.

    For an intentional stop (e.g. doors should remain in semi-open/close position for e.g.

    air ventilation, the door can be stopped at any position during the opening or closing

    movement.

    In case of power failure the door can be operated manually. Therefore the disengage

    handle at man’s height must be flipped in order to disengage the motor from the gear

    box. Once flipped (disengaged), the door can be moved in any position (push/pull the

    door leafs). After reaching the optimal position, the door must be immediately re-

    engaged to avoid any additional / unforeseen movements. The disengage handle must

    be flipped down in order to re-engage the drive system.

    For safety, during service or maintenance work, make sure position the main switch at

    control unit (A; page 6) in the “OFF” position with a padlock. This is especially crucial

    during work requiring a ladder or scaffold; to avoid accidental operation (by others) of

    the assembly during work period.

    Fastener, screws, weld seams, which are connecting the door frame to the building

    must be checked.

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    Upper track to be controlled of any wear-offs. Clean sliding surface with brush and humid rag.

    Chariots need to be checked on wearing and erosion (out-of-round) by moving manually and slowly the door.

    Main roller: check body and rolls on wearing and erosion

    Suspension, door element / chariot screw (A) connection, stud screw, tightness of the screw. If required, refasten the screws.

    Condition check of thrust bearings

    Check upper rubber profile (C) and clean it with glycerin

    Cleaning of the lower track (if any).

    Stud bolt with locking nut (A) for fixing

    the pin.

    Check of screw, pin and its fixing

    Grease fitting (B) for greasing the pin

    using grease press

    Check condition of thrust bearings

    Check presence of plastic plug on top

    of each hinge

    Function test of the entire locking system

    Cleaning and greasing of all mechanical parts

    Check condition of vertical rubber profiles.

    Control nylon brushes of wearing and seal; if required, adjust the brushes.

    Universal grease, for example Motorex 190 EP or equivalent. Teflon spray or equivalent.

    Verification of closure of control unit box

    Function check of impulse button(s), if installed

    Control of all electrical connections (fastener)

    1CA

    B

    4

  • 090919-800-9

    Control elements

    Verification of components of control unit and signalization and all corresponding

    signal evaluators. If required, perform adjustments.

    End switches for controlling the movement of the door, bar lock switch (optional), and

    reed contact of the wicked door (optional), electrical conduits, check fasteners and

    positions.

    Check condition of cables and connections as well as the function of strain relief

    Check condition of fixing screws of motor

    Check condition of main (mandatory) and secondary safety edges (optional)

    Check functionality of both elements

    Check function of light barrier in door jambs

    Verification and testing of motor protection measures (stopping/reversing time)

    Condition of fixing screws of motor system

    Verification of transmission shaft

    Check the de-coupling of motor system

    Verification of the cabling and fixing of the cables

    Check for any unexpected noises.

    Verification of all safety measurements (e.g. electric eye, safety edges etc.)

    Check for any unknown noises of door and motor system

    Disengage the motor system and open and close manually the door. Check for

    slacks etc.

    BATOR recommends all service & maintenance work to be completed by a certified

    technician.

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    6.2 Door Main

    Frame

    6 months;

    or

    10,000 Check wear / lose screws

    / Welding seams

    6.3 Upper Track

    System

    6 months;

    or

    10,000 Check wear-offs / Dirt

    6.4 Lower track

    (optional)

    6 months;

    or

    10,000 Clean

    Check

    cleaning w/ brush; Check

    of any corrosion

    6.5 Hinges 6 months;

    or

    10,000 Grease wear-off

    6.6 Door lock

    (optional)

    6 months;

    or

    10,000 Check wear-off

    6.7 Rubber sealing

    profiles

    6 months;

    or

    10,000 Clean

    /

    Check

    wear-off, dirt, puncture or

    rips

    6.9 Control Unit 6 months;

    or

    10,000 Check inspect / adjust

    6.10 Control

    elements

    6 months;

    or

    10,000 Check inspect

    6.11 End switches 6 months;

    or

    10,000 Check inspect / adjust

    6.12 Flexible

    conduits

    6 months;

    or

    10,000 Check wear / inspect

    6.13 Safety and

    protection

    elements

    6 months;

    or

    10,000 Check inspect

    6.14 Drive System 6 months;

    or

    10,000 Check inspect / adjust

    6.15 Final check 6 months;

    or

    10,000 Check Inspect

    BATOR recommends an inspection of automated doors two times per year.

    The frequency of the maintenance depends on the operating conditions and service

    frequency per day. BATOR is pleased to provide you a corresponding maintenance

    contract.

  • 090919-800-11

    The cleaning and care of the door serve primarily to preserve the visual appearance

    and is not part of the functional maintenance.

    Do not perform maintenance on direct solar radiation. The surface temperature should

    not be higher than 77° F (25° C).

    The components of the door construct are made of coated steel, safety glass and

    rubber profiles.

    Any cleaning can be accomplished through the use of mild detergents, soap, and water.

    Finish is similar to that of a car.

    Cleaning of embedded lower tracks can be performed with brush and water. Depending

    on operation conditions, cleaning of the lower track is recommended several times per

    year.

    BATOR recommends treating rubber profiles during winter with glycerin.

    For economic reasons, it is recommended to coordinate cleaning with the periodical

    maintenance, since the hinges and the mechanical closure will need to be greased after

    the cleaning.

    Always position control unit in the “OFF” position and secure with a . Disengage

    motor from the door with the help of the disengage lever.

    Cleaning of the drive system with water; if required with light alkaline detergents and

    sponge or rag.

    Prior to returning the assembly to service, dry from the switches of the

    bar lock and wicked door (12; page 4 and 5)

    The cleaning and care of the door system in not integrated in the maintenance contract

    of BATOR.