ASSA ABLOY RapidProtect RP300 RapidProtect Door Operating instructions

Operating instructions
RapidProtect RP300
6410R0193
2009 ALBANY Door Systems GmbH.
All rights to the door and the related operating instructions are protected.
Reproduction of the door system will be followed by legal action.
These operating instructions may not be reprinted or otherwise reproduced without
the written consent of ALBANY Door Systems.
The general terms and conditions of ALBANY Door Systems GmbH shall apply.
ALBANY Door Systems reserves the right to make technical changes.
These operating instructions are an integral part of the door. The original operating
instructions were produced in German. This is a translation from the German original.
Manufacturer
ASSA ABLOY Entrance Systems
ASSA ABLOY Entrance Systems AB
Lodjursgatan 10
SE-261 44 Landskrona
Sweden
Internet : www.albanydoors.com
E-mail: [email protected]
E-mail: [email protected]
ALBANY Door Systems, USA
975A Old Norcross Road
Lawrenceville, GA 30046
Phone: +1 (0) 770 338-5000
Internet : www.albanydoors.com
E-mail: [email protected]
E-mail: [email protected]
E-mail: [email protected]
Contents
1
Introduction ........................................................................................................... 5
1.1
Other applicable documents.................................................................................... 5
1.2
Declaration of conformity......................................................................................... 5
1.3
Amendments and validity ........................................................................................ 5
1.4
Storage.................................................................................................................... 5
1.5
Target group............................................................................................................ 5
1.6
Conventions ............................................................................................................ 5
1.6.1
Warnings ................................................................................................................. 5
1.6.2
Operations............................................................................................................... 6
2
Safety ..................................................................................................................... 7
2.1
General safety information ...................................................................................... 7
2.2
Personal protection ................................................................................................. 7
2.3
Operator’s duty of care ............................................................................................ 8
2.4
Intended use ........................................................................................................... 8
2.5
Environmental conditions ........................................................................................ 9
2.6
Safety features ........................................................................................................ 9
2.6.1
Electrical safety mechanisms .................................................................................. 9
2.6.2
Additional safety systems ........................................................................................ 9
2.7
Residual risks .......................................................................................................... 9
3
Product description of the door ......................................................................... 10
3.1
Operation and design ............................................................................................ 10
3.2
Door components .................................................................................................. 11
3.3
Control system ...................................................................................................... 11
3.4
Drive unit ............................................................................................................... 12
3.5
Type plate (example)............................................................................................. 12
3.6
Technical data ....................................................................................................... 12
4
Operation ............................................................................................................. 13
4.1
Safety .................................................................................................................... 13
4.2
Operation .............................................................................................................. 13
4.3
Faults .................................................................................................................... 13
4.3.1
Mechanical faults .................................................................................................. 14
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4.3.2
Electrical faults ....................................................................................................... 14
5
Assembly and dismantling ................................................................................. 15
5.1
Inspection of the delivery ....................................................................................... 15
5.2
Preparation for assembly ....................................................................................... 15
5.3
Assembly ............................................................................................................... 16
5.4
Dismantling ............................................................................................................ 29
6
Lifecycle ............................................................................................................... 30
6.1
Commissioning ...................................................................................................... 30
6.2
Maintenance and cleaning ..................................................................................... 30
6.2.1
Safety information .................................................................................................. 30
6.2.2
Inspection plan ....................................................................................................... 30
6.2.3
Cleaning and care .................................................................................................. 31
6.3
Decommissioning................................................................................................... 31
6.4
Transport and storage............................................................................................ 32
6.4.1
Transport ............................................................................................................... 32
6.4.2
Storage .................................................................................................................. 32
6.5
Disposal ................................................................................................................. 32
7
Appendix .............................................................................................................. 33
7.1
RapidProtect 300 technical data: ........................................................................... 33
7.2
Maximum opening and closing speeds and times ................................................. 34
7.3
Curtain deflection ................................................................................................... 35
7.4
General drawing..................................................................................................... 36
7.5
Fixing plan ............................................................................................................. 37
7.6
Inspectionplan ........................................................................................................ 38
7.6.1
Service intervals..................................................................................................... 39
7.6.2
Annotations to inspection plan ............................................................................... 39
7.7
Manufacturer’s certifications .................................................................................. 40
7.7.1
Declaration of Incorporation ................................................................................... 40
7.7.2
EC Declaration of Conformity ................................................................................ 40
7.7.3
Prototype test ......................................................................................................... 40
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1
Introduction
These operating instructions are intended for use with doors in the RapidProtect 300
series with the associated control system. They constitute part of the product and
describe how to use the product properly and safely throughout the product lifecycle.
1.1
Other applicable documents
The operating instructions are only valid in combination with the operating
instructions for the control system and the inspection book. Both are supplied on
delivery.
1.2
Declaration of conformity
The declaration of conformity is included in the inspection book and is supplied with
the door.
Modifications that affect the technical data specified in the operating instructions and
proper use, i.e. that materially change the machine, will invalidate this manufacturer’s
declaration of conformity!
1.3
Amendments and validity
The information contained in these instructions constitutes the technical
specifications applicable at time of press. Significant changes will be incorporated
into a new edition of the user manual. The document and version number of these
instructions can be found in the footer.
1.4
Storage
Keep these operating instructions in the storage bag inside the switchbox or, for
doors with an MCC control system, in the supplied document box.
1.5
Target group
These operating instructions are intended for trained, qualified and authorised staff.
All settings and, in particular, repairs and maintenance, may only be performed by
employees of the manufacturer or other trained specialists.
1.6
Conventions
This section explains the conventions used in these instructions for safety information
and operations.
1.6.1
Warnings
Warning notices refer to dangers to the life and health of people or to the machine,
equipment or the environment.
The notices applied directly to the door must be followed and kept in legible
condition.
Warning notices in this document follow the pattern below:
If the danger is an electrical risk, the appropriate pictograms are used:
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SIGNAL WORD
Danger
Consequences
Precautions
SIGNAL WORD
Danger
Consequences
Precautions
The following warning levels are used:
Signal word
Hazard level
Consequences of non-observance
DANGER
Immediate grave danger
Death or serious physical injury
WARNING
Potential grave danger
Death or serious physical injury
CAUTION
Potential hazardous situation Minor physical injuries, material
damage
This symbol identifies information that will aid better understanding of how the door
works.
Important information
1.6.2
Operations
Aim
1. Step
→
Result of the step (optional)
2. Step…
Result of the operation (optional)
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2
Safety
2.1
General safety information
These operating instructions contain important information for commissioning,
operating, transporting, storing and maintaining the door safely and properly.
• Read the operating instructions carefully and keep them in a safe place.
• Take particular note of the information in this chapter. Also note the special safety
information included in the other chapters.
• Only use the door for the intended purpose. If ownership of the door is passed to a
third party, make sure that these operating instructions are also supplied.
2.2
Personal protection
• No special personal protection equipment is required for use of the door.
Nevertheless, the door may only be used by trained and authorised staff.
Furthermore, the conditions pertaining in the operation where the door is used also
apply.
• If the electric drive unit should fail, the door can be opened manually using a hand
crank. In this situation, the power supply to the drive unit is cut.
WARNING
Risk of injury
It can lead to injuries by simultaneous starting of the motor during inserting the
emergency hand crank.
Always switch off the main switch before using the emergency hand crank.
• Do not reach into the side parts of the door or in the area of the top roll when it is
in operation.
• Untidiness can cause accidents. Keep the working environment in the immediate
vicinity of the door tidy.
• Do not climb the door.
• Whenever work is performed on the door, move the main switch to “Off” or “0”
(disconnection from the mains) and secure it against accidental re-activation.
• Stop the door immediately in the event of mechanical or electrical damage,
especially if the mains or control cables are damaged.
• Only operate the door at the approved supply voltage and mains frequency.
• Only use accessories or attachments that have been approved by the
manufacturer for use with this door.
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2.3
Operator’s duty of care
The door has been designed and manufactured in light of a risk analysis and with
careful selection of the standards to be observed and other technical specifications. It
is therefore state-of-the-art and guarantees the highest possible degree of safely.
However, this level of safety can only be achieved in practice if all the necessary
measures are taken. The operator of the door has a duty of care to plan these
measures and check their execution.
Note the following information on safe operation of the door:
• Only employees of the manufacturer or other trained staff may install, commission,
inspect, maintain, repair and dismantle the door.
• Only appropriately trained, qualified and authorised staff may operate the door.
• The machine must only be used for its intended purpose.
• The machine must only be operated in perfect operating condition. The safety
mechanisms in particular must be checked regularly for operability.
• Always keep the complete operating instructions in legible condition at the location
where the door is installed.
• Run regular training for staff on all relevant issues of health and safety, the
operating instructions and in particular the safety information contained in the
instructions.
• Leave all safety and warning notices applied to the machine and ensure that they
are legible.
2.4
Intended use
Unless otherwise specified, our doors have been developed and tested under normal
conditions. We are happy to advise you on the choice of suitable options for use
under special conditions (e.g. permanent load on one side from temperature,
overpressure/vacuum or particular environmental influences etc.).
The door is designed to be a protective barrier and offers the following protection:
• visible barrier for welding installations or machinery centres
• prevention of movement of persons and access to hazardous areas
• protection against a temporary increase of heat radiation up to 90°C, depending
on the curtain
• noise protection to -20 dBA, depending on the curtain
• protection on milling machines and machinery centres against expulsion of broken
tools or machine parts. The energy absorption under DIN EN 13128 is between
130J and 378J, depending on the curtain
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2.5
Environmental conditions
Depending on the model, the doors are designed for installation as interior doors and
for use under normal environmental conditions (10°C - 45°C).
2.6
Safety features
2.6.1
Electrical safety mechanisms
The photocells and control system are subjected to an internal test before the door
descends (safety category 2 / performance level c under EN ISO 13849-1 “Safetyrelated parts of control systems”). If a fault is detected, the power supply to the drive
unit is cut.
2.6.2
Additional safety systems
2.6.2.1 Sensors
Depending on the application, it is sensible to add more sensors as safety systems,
e.g. for applications with a high level of movement of persons and for doors less than
3 m high that do not have the additional safety mechanism of the user seeing the
closing door.
Albany Door Systems offers a wide variety of safety systems for RapidRoll doors
including light curtains, motion sensors, induction loops etc. We advise you to ask us
for specialist advice on site about your specific application.
A top roll cover is specified for doors less than 2.3 m high.
2.7
Residual risks
The door has been designed and manufactured in light of a risk analysis and with
careful selection of the standards to be observed and other technical specifications. It
is therefore state-of-the-art and guarantees the highest possible degree of safely.
However, this level of safety can only be achieved in practice if all the necessary
measures are taken. In particular, when the door is operated manually, these
persons must have been instructed in the use of the door and the potential danger
involved in walking under the closing door must be highlighted.
The door is not designed for constant manual activation.
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3
Product description of the door
The following sections explain the operation and design of the RapidProtect 300
door.
3.1
Operation and design
RapidProtect 300 doors are vertically opening, rapid roll doors for use in machinery
protection. They comprise two side frames, a top roll with an electric drive, the door
curtain and a bottom profile.
The side frames guide the bottom profile and flexible door curtain that is rolled onto
the top roll when you open the door.
Safety limit switches that indicate the closed position of the door independently of the
door control system can be installed in both side frames to monitor the process.
When the door is closed, the curtain is rolled off the top roll and descends under the
weight of the bottom profile and the curtain itself.
3.1.1.1 Safety systems
All RapidRoll doors are fitted with compliant protection of the main bottom edge.
The table below lists the safety systems fitted to the door.
Type
Protection of the bottom edge
Breakaway mechanism *)
RP 300
electric safety edge or pre-running
photocell
none
*) The type of breakaway mechanism depends on the type of bottom edge protection
All doors are also fitted with an integral safety photocell in the side frames (optional
on the RapidProtect 300 with pre-running photocell). If the photocell is blocked, the
door curtain stops and reverses direction.
The operation of the pre-running photocell is tested every time the door starts to
close. The electric safety edge is monitored permanently whenever the door closes.
If a fault is detected, the power supply to the drive unit is cut.
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3.2
Door components
1
2
3
4
5
6
7
8
9
Safety photocell
Door curtain
Top roll
Optional: roll cover (aluminium);
fitted as standard on doors < 2.3
m high
Optional: Motor cover (plastic,
powder-coated steel);
recommended for doors < 2.3 m
high with movement of persons
Drive unit
Electrical switchbox
Side frames
Continuously monitored electric
safety edge
The stationary safety photocell (1) monitors the closure area of the door. The door is
prevented from closing or stopped if the light beam is broken.
Depending on the model, the door curtain (2) is made from a coated, colours and
woven polyester monofilament or transparent/coloured PVC with draught strips.
(silicon-free)
The roll top (3) is an aluminium pipe with shaft stubs glued in.
The drive unit (6) contains an electric motor, transmission, limit switch and pulse
counter.
The electrical switchbox (7) contains the ACS 50 or MCC control system, depending
on configuration.
The side frames (8) are made of aluminium.
If the safety edge (9) is touched, the door immediately returns to the open position.
Alternatively, pre-running photocells can be used.
3.3
Control system
Doors in the RapidProtect 300 series can be operated with a high-performance
frequency converter control that facilitates a gentle acceleration and braking of the
door. Alternatively, depending on the model, an ACS 50 contactor control can be
used.
The maximum opening and closing speeds for the individual doors can be found in
the table in the appendix.
DANGER
Danger of electrocution
Doors that are not operated with the recommended drive unit or control
system can cause electrocution.
Only operate the door with an original drive unit and a control system from the
manufacturer.
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3.4
Drive unit
The RapidProtect 300 is operated with an electric drive unit. The drive unit is fitted at
the top of the door, in a position that cannot be reached from the floor, with vibration
dampening. The drive unit can be fitted on the left or right as the customer wishes.
The temperature of the drive unit is monitored by a thermocouple that cuts the power
supply to the drive unit if it overheats.
3.5
Type plate (example)
(the actual data will vary depending on the specific door)
3.6
Technical data
The appendix contains the following technical data:
Technical data
Door dimensions
Dimensions of the fitted door
Installation space
Fixing points
Contained in
General drawing
Fixing plan
All other technical data relating to the door can be found in the appendix.
Subject to technical changes arising in the course of product maintenance.
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4
Operation
This chapter describes the operation of the door irrespective of the control system
used. Please read the respective control system manual for a description of control
system.
4.1
Safety
• Do not use the door for any purpose other than that intended.
• Take the door out of operation immediately in the event of damage (mechanical or
electrical). This applies in particular to damage to the mains or control cables.
• Only use accessories or attachments that have been approved by the
manufacturer for use with this door.
• Also note the safety information in chapter 2.
4.2
Operation
The door has an electric drive unit and can be operated both using the button on the
door control system and via additional, external impulse generators and safety
mechanisms.
Generally the Open, Stop and Close buttons on the door control system should be
used during setup, maintenance and repair of the door.
In normal operation, the door is controlled via external signal sources such as rope
pull switches, induction loops, radar or radio sensors or palm buttons connected to
the door control system via potential-free contacts.
Machine protection doors can be operated via a higher-level control system.
The choice of impulse generator is part of the design and setup of the door and
control system and may only be performed by trained specialists.
4.3
Faults
DANGER
Danger of personal injury and material damage
Improper fault clearance can lead to damage to the product and serious injury
to staff
Faults should only be cleared by appropriately qualified staff.
Switch off the main switch to secure the door against accidental re-activation.
Lock the main switch to secure it against re-activation or ensure safety shutdown
of the machine by a second person.
Secure the area of activity around the door.
If the fault cannot be cleared, contact the supplier’s or manufacturer’s customer
service.
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4.3.1
Mechanical faults
Fault
Possible cause
Necessary actions
Door opens or
closes by itself
Brake on motor is defective
Brake incorrectly set
No power supply
Electrical connections are
defective
Fuse has blown
Door has been installed
incorrectly
An object has caught in the
rolled curtain
Replace brake
Set brake
Connect the door to the mains
Motor not
working
Curtain rolls up
crookedly
4.3.2
Check connections
Replace fuse
Call customer service
Close the door and check for
extraneous objects
Electrical faults
Fault
Possible cause
No mains power
Control system fuse
blown
Door not working Main switch off
Emergency stop circuit
broken
Door does not
close
Necessary actions
Check mains power supply/fuse
Check control system and replace fuse
Turn on control system (main switch)
Check emergency stop circuit. Bridge
unnecessary stop inputs as per wiring
diagram.
Up pulse is permanently
Check impulse generator
on
Safety photocell blocked Check safety mechanisms
Door only closes
Alternating switching set Check set control function
on next pulse
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5
Assembly and dismantling
DANGER
Risk of injury
Improper handling of the packaged door can lead to injury.
Place palette on an even surface.
Do not remove palette before starting assembly.
5.1
Inspection of the delivery
The door is largely pre-assembled on delivery. The side frames, roll cover, motor
cover (if supplied), fixing materials and control system are secured to a transport
frame (wooden palette).
• Check door for damage incurred during transit
• Check that the delivery is complete by comparing it with the order documentation
• Notify Albany Door Systems and report any damage prior to proceeding with
installation
5.2
Preparation for assembly
DANGER
Risk of injury
Incorrect assembly of the door can lead to injury.
Isopanel walls, chequer bricks and light partition walls must be checked for
their suitability for assembly.
The door may only be assembled by trained staff.
The door may only be assembled by the manufacturer or an installation firm
approved by the manufacturer.
Make the following preparations before assembling the door:
• Inspect the installation site for the necessary fixing points and assembly
requirements: assemble a substructure or other suitable fixing options if
necessary. Screw the upper fixing points to a steel substructure or concrete
element. The fixing plan can be found in 7.5.
• Measure clearance dimensions (width and height) of the door opening and
compare with the order.
• Cordon off the installation site against people and vehicle movements.
• Remove shrink-wrap from the packaged door.
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5.3
Assembly
1. Check the door for possible transport
damage and check the completeness
against the delivery documentation.
2. Side frames, bottom profile and top roll
cover.
3. Top roll with rolled and secured door
curtain.
4. The drive unit and assembly materials
are supplied in a box.
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A
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13. The bearing must be fitted from inside
on the other side (short shaft stub) with two
M10x30 hex head screws/washers/nuts.
14. Now place the motor on the drive
shaft. Check the plain key connection.
Check that the position is secure, use
lifting tools if necessary.
15. Secure the torque support to the top
plate using four M8x30 hex head screws/
nuts/ washers and 2 additional spacers.
16. Remove the fixing strap from the door
curtain.
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1
17. Disengage the brake from the motor (1)
and lower the door curtain using the hand
crank (2).
This crank can be used as an emergency
manual opening mechanism in the event of
a fault.
18. Lower the door curtain to working level
and slide on the bottom profile.
19. Undo the screws on the cover/guide
piece. Pre-running photocell: side frames
with pre-assembled cable carrier
chain/guide piece. Safety edge: run the
cable through the lower slider channel and
secure with cable ties.
20. Insert the slider clamp diagonally into
the bottom profile and snap into the side
frame guide.
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21. Slide the slider into the bottom profile
and screw to the bottom profile and clamp
using two M8x40 oval head screws and
washers. The door can run even without the
cover assembled so that the limit switches
can be set.
22. Centre-align the bottom profile so that
the ends of the door curtain protrude by the
same amount on both sides of the bottom
profile.
23. Drill in the door curtain on the right and
the left side d=5,5mm holes through the preboring of the bottom profile. Fix each side
using an M5x12 socket head screw / nut /
washer.
24. Insert the side frame cover slightly
diagonally (5° - 10°), slide into the support
channel and screw tight with the stiffener.
Make sure that the guide remains 12 mm
wide.
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25. Brackets for assembling the top roll
cover. The brackets must be screwed to the
top plates from inside using two M8x20 hex
head screws/nuts. The same screws/nuts
are also used for the motor cover bracket.
26. Secure the top roll cover using four
M8x16 oval head screws / large washers.
Standard drive unit
S1 EMERGENCY OPEN S4 CLOSE
S2 EMERGENCY CLOSE S5
DEACTIV.. STAT. PHOTOCELL
27. Connect the electrical connections for
the drive unit. Set the cam-operated limit
switches taking account of the limits.
For doors with MCC, only use limit switches
S1 and S3!
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28. Standard drive unit: Cam-operated
limit switch:
Once this has been roughly adjusted,
tighten screw A and do not loosen again if
possible (paint over to secure). Use screw
B for fine adjustment of the limits.
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29. Adjust cam-operated limit switch S4 in
such a way that it is switched at an opening
height of 30-50 mm.
30. Adjust cam-operated limit switch S5 in
such a way that it is switched at an
opening height of 300-400 mm.
32. Since there is no risk of injury or
damage up to a height of 400 mm, the trip
point for the photocell can be moved to this
height (the safety edge is still active).
The emergency limit switches are
automatically preset by the limit switch
settings.
The switch point for the emergency limit
switches may need to be corrected using
the fine adjustment screw such that the
door still stops and poses no risk in the
event of inversion of the turning gear or
failure of the operational limit switches.
31. Use the supplied holders to secure the
control system and the display to the side
frame or the wall.
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33. Position of the fixing screws.
34. Secure the holder to the top plate with
two M8x20 hex head screws/nuts. (The
same screws/nuts are also used for the top
roll cover bracket)
A.) MCC not on the side frame
B.) MCC on the side frame
35. Detach at the perforation.
Apply edge protection and cover.
A.): Only detach the corner if this is
necessary for the cable feed-through.
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36. Secure the motor cover to the holder
using two M8x16 oval head screws / large
washers.
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Doors with magnetic limit switches!
37. The magnetic switch is built into the
side frame along with the connector and
holder for height positioning. The cable and
connector are supplied.
The magnet and holder are assembled on
the bottom profile.
Note: various types of switches can be
used!
38. Connect the magnetic switch to the
control system in accordance with the wiring
plan. Screw on the connector. Lower the
door to the lower limit.
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39. Check the safety relay to see whether
the magnetic switch is active. The switch
should be approx. 8mm above the Magnet
of the bottom profile. Move the bottom
profile horizontally and vertically to check
that the signal is still being transmitted.
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40. Allow the door to run for at least 5
cycles, and then check the output signals
from the switches. The switch can be
positioned vertically in the screw channel of
the side frame.
41. When the magnet arrow matched to
the switch arrow, there should be about
9mm clearance to the stopper for the
bottom profile.
Fit the transparent cover on the side frame
(option).
Doors with roller lever switches!
42. The roller lever switch and holder are
built into the side frame. Connect the roller
lever switch to the control system in
accordance with the wiring plan.
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43. Lower the door to the lower limit.
Check the safety relay to see whether the
roller lever switch has been triggered.
Move the bottom profile horizontally and
vertically to check that signals are still
being transmitted.
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44. Check that both switches are
transmitting a signal at the same time. The
switch can be positioned in the screw
channel of the side frame. Allow the door to
run for at least 5 load changes and check
that both switches are transmitting a signal
at the same time.
45. Slide the chain drive into the top roll in
the specified position (45° steps) on the
floor, attach to the top plate using at least
three M10x18 hex head screws/washers.
Secure the fixing plate (usually parallel to
the top plate) with four M8x20 countersunk
screws. Lay the chain over both sprockets
and join with the locking link.
46. Use a crane or fork-lift truck etc. to lift
the top roll and secure the top plates to the
wall/substructure. Tighten the screws on the
fixing plate twice more. (mounting hardware
is not supplied)
47. Pull the two springs on the chain
tensioners over the screw head using
needle-nosed pliers on the spring eyelet
disc.
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48. Insert the chain drive cover diagonally
under the housing and then secure to the
opposite side with two M8x16 hex head
screws.
49. Slide the first part of the two-part
motor cover before drive and fix it with two
M12x25 hex head screws/washers to the
intended position (in 45° steps) on the
chain drive box. Slide drive on shaft, fix it
with two M12x120 screw/bush and secure
the shaft with M8x20 screw/large washer.
50. Torn out the square perforation on the
place needed for the cable feed. Apply edge
protection.
Slide the second part of motor cover over
drive unit/first part of cover. Fix the both
motor cover parts together with at least four
M6x12 oval head screws/washers.
51. Without chain drive, not vertically
hanging: the first part of cover will be fixed
with two M12x25 hex head screws/nuts
and 4 distance-washers directly on the
gear box.
Torn out torque-arm/cable-feed perforation.
Fix decor-plate with two M10x20 oval head
screws/nuts on the second part of cover.
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Power cable length > 2 m
Klick!
52. Two positions of the drive unit and more 53. To reduce the EMC one Snap-onthan 50 different installation options for the
Ferrite should be fixed on each end of the
chain drive and Vario drive are possible.
display cable. (delivered loose with display
cable)
5.4
Dismantling
Simply perform steps in the assembly instructions in reverse order to dismantle the
door.
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6
Lifecycle
6.1
Commissioning
Please read the information in the appropriate control system manual.
6.2
Maintenance and cleaning
Please contact the supplier or manufacturer for maintenance / fault clearance /
repair.
ASSA ABLOY Entrance Systems
ALBANY Door Systems - Service
Am Mondschein 25,
D - 59557 Lippstadt, Germany
ALBANY Door Systems, USA
975A Old Norcross Road
Lawrenceville, GA 30046
Tel. +49 (0) 2941 766–0
Fax +49 (0) 2941 766–294
Internet : www.albanydoors.com
Phone: +1 (0) 770 338-5000
Internet : www.albanydoors.com
E-mail: [email protected]
6.2.1
E-mail: [email protected]
E-mail: [email protected]
Safety information
Only the manufacturer or trained staff may maintain, inspect or service the door.
• Disconnect the power supply using the lockable main switch in the switchbox prior
to any maintenance and cleaning work.
• Use a testing device to make sure that there is no power to the switchbox.
• Make sure that all scaffolding, ladders etc. comply with the applicable safety
regulations.
• Cordon off the work area. When the work is finished, remove any leaked lubricants
and tools or other materials from the floor.
6.2.2
Inspection plan
Note all maintenance, repair and modification work in the inspection list that is
included in the inspection book for every door to ensure that any changes can be
traced.
Document the requisite services, inspections and implementation notes in the
inspection plan that can be found in the inspection book.
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6.2.3
Cleaning and care
6.2.3.1 Curtain
CAUTION
Risk of material damage
Improper cleaning of the curtain may damage the surface
Do not use glass cleaners as they contain aggressive substances.
Never use abrasive cleaners, scrapers, razor blades, filling knives etc.
Clean with warm water, a low dose of a gentle plastic cleaner and a clean, soft
and non-fluffy cloth.
6.2.3.2 Door frame
CAUTION
Risk of material damage
Improper cleaning of the door frame may damage the surface
Do not use pressure cleaners.
Remove dust with a soft cloth.
Remove heavier soiling with water and an ordinary liquid cleaner.
Metal surfaces that are soiled with grease or oil should be cleaned with an agent
that contains a solvent.
6.2.3.3 Surrounding area
After maintenance work in particular, the floor in the immediate vicinity of the side
frames may be soiled. Remove this with care.
6.3
Decommissioning
• Follow the assembly instructions during dismantling.
• Disconnect the power from the door before dismantling. In particular, make sure
that all the springs are de-tensioned.
• Check parts that are subject to wear and tear and replace if necessary before
reassembly.
• Check connectors, do not kink cables.
• Store all the components in a clean, dry place.
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6.4
Transport and storage
6.4.1
Transport
The individual door components may only be removed from the transport palette at
the installation site.
DANGER!
Risk of injury
Improper transport can lead to the load slipping and falling.
Follow the public safety regulations during transport to the installation site.
Secure the door against tipping and slipping.
Lift the door at its centre of gravity to prevent it slipping sideways.
6.4.1.1 Dimensions and weights
Dimensions of the transport palette and door
[mm]
Drive unit and control system
palette [mm]
Door
Length
Width x Height Length x Width x Height
RP300
W or H + 500
500 x 400
800 x 600 x 500
RP300 USA
W or H + 600
770 x 580
included in the crate
Weight of door with palette [Kg] (intermediate values can be interpolated)
W x H [m]
2x2
2 x 2.5
3x3
4 x 3.5
RP300 / (USA)
140 / (165)
175 / (200)
210 / (240)
270 / (300)
(W = Width of door opening) (H = Height of door opening)
6.4.2
Storage
The partially pre-assembled door is delivered on a transport/assembly palette and is
shrink-wrapped. If the packaging is undamaged, the door can be stored outside for a
few days.
6.5
Disposal
The door packaging can be returned to the manufacturer. Defective door
components must be disposed of in an environmentally friendly way by the customer.
Defective electronic components must be disposed of as special waste.
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7
Appendix
7.1
RapidProtect 300 technical data:
The table below contains the technical data for the RapidProtect 300 series doors.
You can also find a brief summary of the maximum opening and closing speeds in
section 7.2.
Door principle:
Direction of movement:
Application:
Available sizes:
W min:
W max:
H min:
H max:
Installation site:
Door frame:
Bottom profile
Top roll
Curtain:
Roll cover 1)
Motor cover
Drive unit:
Control system:
Max. opening speed MCC:
Max. closing speed MCC:
Max. opening speed ACS 50:
Max. closing speed ACS 50:
MCC mains connection:
MCC with upstream transformer:
ACS 50 mains connection:
ACS 50 with upstream transformer:
Motor power:
Control supply:
Motor protection rating:
Typical no. of cycles / min.:
Noise level:
RapidProtect 300
Roller door
vertical
Interior door
750 mm
4000 mm
750 mm
3500 mm
Inside a structure
Aluminium
Aluminium
Aluminium
PVC or woven polyester monofilament
Aluminium
Powder-coated steel
electric
MCC, ACS50
2.4 m/s
1.8 m/s
1.0 m/s
1.0 m/s
3/(N)/PE 380-480V, 50/60Hz, 12A fuse
3/(N)/PE 220V, 230V, 500V, 50/60Hz
3/(N)/PE 230V, 50/60Hz, 10A fuse
3/(N)/PE 380-415V, 50/60Hz, 6,3A fuse
3/(N)/PE 440-500V, 50/60Hz
0.75 KW
24 V DC
IP55
Max. 1 with ACS 50, max. 5 with MCC
70 dBA
1) A top roll cover is required for doors with a height of < 2300 mm in order to
comply with the requirements of standard EN 13241-1.
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7.2
Maximum opening and closing speeds and times
Door height
MCC
MCC
Open max. (*)
m/s (UL-drive)
Close max. (*)
m/s (UL-drive)
Opening time (*)
s (UL-drive)
Closing time (*)
s (UL-drive)
RP300 KL
1.0m (**)
1.7 (1.6)
1.2 (1.2)
1.2 (1.3)
1.5 (1.5)
RP300 VL
1.0m (**)
1.7 (1.6)
1.5 (1.5)
1.2 (1.3)
1.3 (1.4)
RP300 KL
1.5m (**)
2.0 (1.9)
1.2 (1.2)
1.4 (1.6)
1.8 (1.9)
RP300 VL
1.5m (**)
2.0 (1.9)
1.6 (1.5)
1.4 (1.6)
1.6 (1.7)
RP300 KL
2.0m (**)
2.2 (2.0)
1.3 (1.3)
1.6 (1.8)
2.3 (2.3)
RP300 VL
2.0m (**)
2.2 (2.0)
1.7 (1.6)
1.6 (1.8)
2.0 (2.0)
RP300 KL
2.5m (**)
2.3 (2.1)
1.4 (1.3)
1.9 (2.1)
2.6 (2.7)
RP300 VL
2.5m (**)
2.3 (2.1)
1.8 (1.7)
1.9 (2.1)
2.3 (2.3)
RP300 KL
3.0m
2.3 (2.2)
1.2 (1.2)
2.1 (2.2)
3.5 (3.5)
RP300 VL
3.0m
2.3 (2.2)
1.6 (1.5)
2.1 (2.2)
2.8 (2.8)
RP300 KL
3.5m
2.4 (2.3)
1.3 (1.3)
2.3 (2.4)
3.9 (3.9)
RP300 VL
3.5m
2.4 (2.3)
1.8 (1.6)
2.3 (2.4)
3.2 (3.2)
Door height
ACS 50
ACS 50
Open/Close max. (*)
m/s
Opening time / Closing time (*)
s
RP 300 KL
1.0 m
0.75
1.8
RP 300 KL
1.5 m
0.80
2.2
RP 300 KL
2.0 m
0.85
2.8
RP 300 KL
2.5 m
0.90
3.3
RP 300 KL
3.0 m
0.95
3.9
RP 300 KL
3.5 m
1.00
4.4
KL = Safety edge
VL = Pre-running photocell
(*) The values listed are guide values which may vary from the min/max shown on individual
doors. In particular longer cycle times during the process may lead to substantial changes.
(**) speed is reduced if DW > 2.5m
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7.3
Curtain deflection
Torbreite = Door Width
Width
Height
2,2 m
2,2 m
2,2 m
2,2 m
2,2 m
2,2 m
2,2 m
2,2 m
2,2 m
2,2 m
1,0 m
1,5 m
2,0 m
2,5 m
3,0 m
3,5 m
4,0 m
F
S
F
S
F
S
F
S
F
S
F
S
F
S
[N] [mm] [N] [mm] [N] [mm] [N] [mm] [N] [mm] [N] [mm] [N] [mm]
80
90
80
95
80 100
80 105
80 110
80 115
80 120
95 100 105 100 110 100 115 100 125 100 130 100 135
100
95 150 125 150 125 150 135 150 145 150 155 150 160
150
200 100 200 135 200 135 200 150 200 160 200 175 200 180
250 105 250 140 250 140 250 170 250 180 250 195 250 200
300 110 300 145 300 150 300 185 300 195 300 215 300 220
400 115 400 150 400 165 400 205 400 220 400 245 400 250
600 125 600 180 600 200 600 230 600 255 600 280 600 290
800 145 800 190 800 225 800 260 800 285 800 310 800 325
1000 155 1000 205 1000 245 1000 270 1000 295 1000 315 1000 330
*295 *110 *90 *110 *110 *115 *120 *125 *125 *135 *130 *145 *135 *150
*The bottom profile rises 10 mm and the Schmersal switch is deactivated
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7.4
General drawing
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7.5
Fixing plan
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7.6
x
x
x
x
Inspectionplan
Installation fixings
retighten screws
1
Drive unit
Check brake condition and function of brake release lever
Check retainer of torque arm and buffer
1
1
Top roll
retighten bearing retainer
1
drive shaft
retighten flange bearing of drive shaft
Check fixed position of shaft extension on the aluminum top roll
1
1
Door leaf
Check leaf for cuts and grinding signs at the guiding
Check tight fit and wear & tear signs of wind taps (eventually replace)
Check connection between door leaf and bottom beam
1
1
1
Bottom profile
Check tight fit and condition of profile, guiding pieces, eventually flexible cable
conduit and the gliding pieces - exchange deformed guiding pieces and gliding
pieces
Check condition of safety edge / prerunning photocell, the cable and cable chain
1
1
Side columns
Check fixation and condition of profiles with components
Check cable trail, eventually cable chain for cable
Check installation and function of photocell
Clean photocell optic
1
1
1
3
Control box and additional components (like actuators)
Check completeness of wiring diagram
Check main switch / CEE-plug and control box lock
Check the fixation
2
2
2
Electric functions
Door movement
Check opening and closing position of bottom profile
1
1
Safety devices and actuators
Check function and fixation of limit switches
1
Electric components
Look for mechanical damages
2
Mechanical functions
Check the possibility of the Emergency opening
Roll-up operation of door blade
1
1
x see next page for annotations
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7.6.1
Service intervals
1
2
3
7.6.2
6 months or 100.000 cycles
12 month
Clean upon requirement
Annotations to inspection plan
7.6.2.1 Brake
If the gap of the brake cannot be adjusted to a distance of 0,2 mm, the brake must be
changed
7.6.2.2 Wind taps
The material thickness from the square hole to the contact surface to the side column
should not fall below 1 mm
7.6.2.3 Safety edge / prerunning photocell
Let the bottom profile come down on an object. The door must return to final door
position top after touching the object. With prerunning photocell hold the flat hand
vertically below the bottom profile in about 1 m height. The door has to reverse in
final door position without touching or only slight touching of the rubber profile.
7.6.2.4 Function of photocell
Both LED of photocell must be switched on.
Transmitter green LED, receiver red LED
The red LED of the receiver turns off after interruption of the photocell. The door
must go up to final door position top after interruption of the photocell.
The photocell optic can be cleaned with a soft cloth and water upon requirement.
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7.7
Manufacturer’s certifications
7.7.1
Declaration of Incorporation
Albany Door Systems declares that the RapidProtect RP 300 is an incomplete
machine under the Machinery Directive 2006/42/EC. The product is a machine
protection door with the property of separating the hazardous areas of another
installation and thereby reducing the risk to people and goods. (Valid from
01.01.2010)
Commissioning of our door is prohibited until it has been determined that the
installation incorporating our door complies with the provisions of the EC Machinery
Directive.
7.7.2
EC Declaration of Conformity
We, Albany Door Systems, declare that a door sold by us meets the fundamental
health and safety requirements of all relevant European Directives and is therefore
compliant with these Directives. The EC Declaration of Conformity is the basis for CE
marking of a complete machine/installation.
7.7.3
Prototype test
The submission of a prototype test represents an additional voluntary proof on the
part of the manufacturer over and above compliance with “Conformity”. A state-run,
state-commissioned or state-approved institution (e.g. professional association or
TÜV) will, on request, test the conformity of e.g. a machine protection door based on
the relevant current norms, regulations and standards specified for their intended
purpose and certify this conformity by issuing a prototype test.
The prototype test remains valid until:
the period of validity stated in the prototype test elapses
or
there is a change to, or nullification of, the relevant norms, standards and regulations
in respect of
issue of the prototype test
or
there is a change in the scope, design or type of use of the product that is the subject
of the prototype test
www.albanydoors.com
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