Ditec NRG100TXE Industrial Sectional Door Automations Instruction Manual

Ditec NRG100TXE Ditech NRG100TRE
Ditec NRG100TXF Ditec NRG140TXE
Industrial sectional door automations – Technical manual (Translation of the original instructions)
www.ditecautomations.com

General safety precautions

ATTENTION! Important safety instructions. Please follow these instructions carefully. Failure to observe the information given in this manual may lead to severe personal injury or damage to the equipment. Keep these instructions for future reference. This manual and those for any accessories can be downloaded from www.ditecautomations.com

This installation manual is intended for qualified personnel only

• Installation, electrical connections and adjustments must be performed by qualified personnel, in accordance with Good Working Methods and in compliance with the current re­gulations
• Read the instructions carefully before installing the product. Wrong installation could be dangerous
• Before in­stalling the product, make sure it is in perfect condition.

The packaging materials (plastic, polystyrene, etc.) should ‘not be discarded in the environment or left within reach of children, as they are a potential source of danger

• Do not in­stall the product in explosive areas and atmospheres: the pre­sence of inflammable gas or fumes represents a serious safety hazard
• Make sure that the temperature range indicated in the technical specifications is compatible with the installation site
• Before installing the motorization device, make sure that the existing structure, as well as all the support and guide ele­ments. are up to standards in terms of strength and stability. Verify the stability and smooth mobility of the guided part, and make sure that no risks of fall or derailment subsist. Make all the necessary structural modifications to create safety clea­rance and to guard or isolate all the crushing, shearing, trap­ping and general hazardous areas
• The motorization device manufacturer is not responsible for failure to observe Good Working Methods when building the frames to be motorized, or for any deformation during use
• The safety devices (photo­cells, safety edges, emergency stops. etc.) must be installed taking into account the applicable laws and directives, Good

Working Methods, installation premises, system operating lo­gic and the forces developed by the motorized door or gate

• The safety devices must protect against crushing, cutting, trap­ping and general danger areas of the motorized door or gate. Display the signs required by law to identify hazardous areas. Each installation must bear a visible indication of the data iden­tifying the motorized door or gate

• Before connecting the po­wer supply, make sure the plate data correspond to those of the mains power supply. An omnipolar disconnection switch with a contact opening distance of at least 3mm must be fitted on the mains supply. Check that there is an adequate residual current circuit breaker and a suitable overcurrent cutout upstream of the electrical installation in accordance with Good Working Me­thods and with the laws in force

• When requested, connect the motorized door or gate to an effective earthing system that complies with the current safety standards

• Before commis­sioning the installation to the end user, make sure that the au­tomation is adequately adjusted in order to satisfy all the fun­ctional and safety requirements, and that all the command, safety, and manual release devices operate correctly

• During installation, maintenance and repair operations. cut off the power supply before opening the cover to ac­cess the electrical parts

• The protection cover of the operator must be removed by qualified personnel only.
  The electronic parts must be handled using earthed antistatic conductive arms. The manufacturer of the motori­zation declines all responsibility if component parts not com­patible with safe and correct operation are fitted

• Only use original spare parts for repairing or replacing products

• The installer must supply all information concerning the automatic. manual and emergency operation of the motorized door or gate, and must provide the user with the operation and safety instructions.

Declaration of incorporation of partly completed machinery

(Directive 2006/42/EC, Annex II-B)
The manufacturer, ASSA ABLOY Entrance Systems AB, with registered office at Lodjursgatan 10, SE-261 44 Landskrona, Sweden declares that the type of equipment with name:Ditec NRG, automation system for sectional doors, comply with the following directives:

EC directives
Signed for and on behalf of ASSA ABLOY Entrance Systems AB by:

• 2006/42/EC (MD);
• 2014/30/EU (EMCD);
• 2011/65/EU (RoHS 2);
• 2015/863/EU (RoHS 2 Amendment) Riggio, 2022-10-26 Matteo

UK regulations
– Supply of Machinery (Safety) Regulations 2008;
– Electromagnetic Compatibility Regulations 2016;
– The Restriction of the Use of Certain Hazardous Substances in Electrical and Electronic Equipment Regulations 2012 (RoHS).

2.1 Machinery directive
Pursuant to Machinery Directive (2006/42/EC) the installer who motorises a door or gate has the same obligations as the manufacturer of machinery and as such
must:
– prepare the technical data sheet which must contain the documents indicated in Annex V of the Machinery Directive; (The technical data sheet must be kept and placed at  the disposal of competent national authorities for at least ten years from the date of manufacture of the motorised door or gate);
– draw up the EC Declaration of Conformity in accordance with Annex II-A of the Machinery Directive and deliver it to the customer;
– affix the EC marking on the motorised door or gate, in accordance with point 1.7.3 of Annex I of the Machinery Directive;
– ensure compliance of the motorised door or gate with safety regulations, by installing the necessary safety devices.

Technical data

 | Ditec NRG100TRE| Ditec NRG100TXE| Ditec NRG100TXF| Ditec NRG140T XE
---|---|---|---|---
Power Supply| 400 V 3~| 400 V 3~| 400 V 3~| 400 V 3~
Frequency| 50 Hz| 50 Hz| 50 Hz| 50 Hz
Power| 0,80 kW| 0,80 kW| 0,80 kW| 0,87 kW
Amperage| 2,20 A| 2,20 A| 2,20 A| 2,30 A
Torque| 100 Nm| 100 Nm| 100 Nm| 140 Nm
Output Speed| 21 rpm| 21 rpm| 21 rpm| 18 rpm
Hollow shaft| 25,4 mm (1”)| 25,4 mm (1”)| 25,4 mm (1”)| 25,4 mm (1”)
Max. door weight| 400 kg| 400 kg| 400 kg| 650 kg
Holding torque| 450 Nm| 450 Nm| 450 Nm| 500 Nm
Motion management| Absolute encoder| Absolute encoder| Mechanical limit switches cams| Absolute encoder
Working temperature *| -20°C ÷ +60°C| -20°C ÷ +60°C| -20°C ÷ +60°C| -20°C ÷ +60°C
Max cycles per hour| 20| 20| 20| 20
Limit switch range (Motor shaft round)| 18| 18| 18| 18
Protection rate| IP54| IP54| IP54| IP54
Unlocking drive| Fast-realese lever| Chain| Chain| Chain
Control panel| EL500E| EL500E| EL400/EL500E| EL500E

• In the range -10°C and +40°C the nominal values are respected. In case of temperature higher/lower performance may dropped.

Axel installation

4.1 Installation
ATTENTION! firmly tighten down all fastening screws.

• Fit the DOD12-14-15 motor onto the drive shaft.
• After having determined the position of the wall bracket, drill the holes and secure the bracket in place with dowels (not supplied).
• Insert the appropriate cotter 3 according to shaft cavity length.
• Secure the metal clamp 4 so as to prevent the risk of the cotter coming out of the shaft.

Chain link-up installation

5.1 Installation
ATTENTION! firmly tighten down all fastening screws.

• After having determined the position of the wall bracket, drill the holes and secure the bracket in place with dowels (not included) 1 .
• Fit the crown wheel onto the sectional door shaft and insert the appropriate cotter depending on shaft cavity length 2 . Fasten the metal clamp 3 so as to prevent the risk  of the cotter coming out of the shaft.
• Link up crown and pinion by means of the chain. Properly tauten the chain by acting on the wall anchoring brackets. Fix the bracket A to avoid that the shaft of the  sectional bends and to guarantee the correct tensioning of the chain.

Electrical connections

6.1 Power supply and limit switch connection with cable NRGCAB and Ditec control unit
It is recommended to use the cable type Ditec NRGCAB to connect Ditec control unit (EL400 or EL500E) to the NRG motor:
– Insert the supply terminal as shown in the 6A and 6B figures (fix it as arrows indicate).
– Insert the limit switch 6 pins clip (L) as figures 6C and 6D illustrate.
WARNING! Before the limit switch adjustment, on the EL500E central unit check the parameter 11 set up.

6.2 Power supply and limit switch connection without cable NRGCAB
If standard cable Ditech NRGCAB is NOT use it is recommended for:

• Motor power supply: remove the black power supply terminal and crimping the connections in compliance with Good Practice and current practices the legend of 6E figure.
• Limit switch connection: use a cable with AMP 0172168 clip on the both extremity and wired up as shown in figure 6F.

Be careful to connect the common and the two senses (down and up) in the shown positions.
WARNING! Before the limit switch adjustment, on the EL500E central unit check the parameter 11 set up.
In case the motor turns in the wrong direction, invert the two wires of the phase (L1, L2 and L3) on the F connector.

Limit switch setting

7.1 Absolute encoder limit switch setting – Ditec NRG100TXE, NRG100TRE AND
NRG140TXE
In Ditech NRG100TXE, NRG100TRE e NRG140TXE such tool is integrated in the limit switch that sends the commands to the external control. Through a telegram of pulses the tool determines and communicates to the electronic controls what the position of the sectional door is and consequently allows to perform the various assigned commands.
The data connection cable (with AMP connector) must be inserted in its place on the encoder L (Fig. 6C) and at the other end, in the control unit. Follow the control instructions and use the external electromechanical control panel in order to determine the up and down limit switch position and of any other auxiliary control.
This limit switch has no microswitches blocking the sectional door in case the limits are overcome. The external control panel will manage the security of the system.
7.2 Mechanical limit switch setting – Ditech NRG100TXF
The 6 cams send to a control unit the signals necessary to know what is the position of the sectional door and execute the various assigned commands accordingly.
The cams function is highlighted by their color (Fig. 7A): 2 green cams for the principal ones (up and down), 2 red cams for security, 2 additional yellow cams for the auxiliary controls.
Check that the motor direction of rotation corresponds to the complementary limit switch, otherwise invert one of the 3 phases of the 400 V 3~ supply.
For the limit switch adjustment use the Allen key 3mm and proceed as follows:

1. Close the door in down limit position, release the A screw of the Down cam, turn the cam till it reaches the microswitch pin, then tighten the A screw.
2. Tune the setting by the B screw of the Down cam till the microswitch is activated.
3. Open the door till the microswitch is free and then close it again.
4. Check and eventually tune the down limit through the B screw of the Down cam.
5. With the door in its closing position, set the safety down limit switch by releasing the A screw of the safety Down cam and turning it till it reaches the microswitch pin (but without activating it), then screw it again. The safety limit switch enables to stop the door, without any damage, in the case that the supply phases are reversed. In case it is activated, the control unit stops electrically the motor and no operation will be possible until the protection is removed.
6. After having activated the sectional door until the upper limit, adjust the Up cam and the safety Up cam in the same way you have done with the Down and security Down cams.

Routine maintenance plan

Perform the following operations and checks every 6 months according to intensity of use of the automation.
Disconnect the power supply 400 V 3~:

• Lubrication of mechanical parts must be performed with door down.
• Make sure that cable and spring breakage device is in perfect working order.
• Check lift-cable wear.
• Make sure that the cables run smoothly in the drums.
• Periodically grease the hinges, ball-bearings, wheel pins, and torsional springs.
• Check for any obstacles that may hinder the wheels from properly running in the guides.
• To check the correct balancing of the sectional automation.
• Make sure that the overhead sliding structure is firmly fastened to the ceiling and perfectly free from any defects, bending or buckling.
• Make sure that there are no loose bolts or screws.
• Absolutely avoid making any changes to the hoisting and/or sliding system.

Connect the power supply (400 V 3~) and check that:

• Limit switches are working properly;
• All control and safety functions are in good working order.

NOTA: only for Ditech NRG100TXE, NRG100TXF and NRG140TXE.
Before manually operate the sectional door, disconnect the main power supply. This prescription must be followed even if the manual operation is equipped with an electrical safety. Remember to re-connect the power supply after the emergency operation.
The door, when moved manually, must never overcome the up or down limit switches otherwise the door risks to be damaged and the limit overcoming activates the safety switches with the result that electrical operation will then be possible only after the intervention of a technician disabling the protection.
To manually activate the sectional door with the manual override with chain you must:

1. Pull the red knob and simultaneously the chain until the override engages the motor shaft and stops,  through the safety micro, the power supply.

2. Manually lift or lower the sectional door by means of the chain.
   WARNING: handle the chain uniformly without tugging.

3. When the manual override is accomplished, pull the green knob to turn the power supply on.
   WARNING: Check that the safety override is unlocked otherwise the motor cannot be activated electrically.

MANUAL DECLUTCH

NOTA: only for Ditec NRG100TRE.
Before manually operate the sectional door, disconnect the main power supply. This prescription must be followed even if the manual operation is equipped with an electrical
safety. Remember to re-connect the power supply after the emergency operation.
The door, when moved manually, must never overcome the up or down limit switches otherwise the door risks to be damaged and the limit overcoming activates the safety switches with the result that electrical operation will then be possible only after the intervention of a technician disabling the protection.
To manually operate the sectional door you must:

1.  pull the red knob, the lever disengages the motor gear from the drive shaft and stops the power supply through the safety micro;
2. manually lift or lower the sectional door;
3. once the emergency operation is accomplished, pull the green knob in order to give power supply again to the system.

All the rights concerning this material are the exclusive property of ASSA ABLOY Entrance Systems AB.Although the contents of this publication have been drawn up with the greatest care, ASSA ABLOY Entrance Systems AB cannot be held responsible in any way for any damage caused by mistakes or omissions. We reserve the right to make changes without prior notice. Copying, scanning or changing in any way is expressly forbidden unless authorised in writing by ASSA ABLOY Entrance Systems AB.
The crossed-out wheeled bin symbol indicates that the product should be disposed of separately from household waste. The product should be handed in for recycling in accordance with local environmental regulations for waste disposal. By separating a marked item from household waste, you will help reduce the volume of waste sent to incinerators or landfill and minimize any potential negative impact on human health and the environment.

ASSA ABLOY Entrance Systems AB
Lodjursgatan 10
SE-261 44, Lands krona
Sweden
© ASSA ABLOY

References

• Ditec - Designed to make a difference: systems that help you make an entrance | Ditec

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