HORMANN Chain Drive Operator ITO 500 FU for Industrial Sectional Doors Installation Guide

Instructions for fitting, operating and maintenance
Chain drive operator ITO 500 FU for industrial sectional doors

Chain Drive Operator ITO 500 FU for Industrial Sectional Doors

Dissemination, as well as duplication of this document and the use and communication of its content, are prohibited unless explicitly permitted. Noncompliance will result in damage compensation obligations. All rights are reserved in the event of patent, utility model, or design model registration. Subject to changes.

Dear Customer,
We are delighted that you have chosen a quality product from our company.

About these instructions

These instructions are original operating instructions as outlined in the EC Directive 2006/42/EC. Read through all of the instructions carefully, as they contain important information about the product. Pay attention to and follow the notes provided, particularly the safety instructions and warnings.
Please keep these instructions in a safe place and make sure that they are available to all users at all times.

1.1 Further applicable documents
The following documents for safe handling and maintenance of the door system must be placed at the disposal of the end user:

• These instructions
• The instructions for the control
• The instructions for the industrial sectional door
• The enclosed log book

1.2 Warnings used
The general warning symbol indicates a danger that can lead to injury or death. In the text, the general warning symbol will be used in connection with the caution levels described below. In the illustrated section, an additional instruction refers back to the explanation in the text section.

DANGER
Indicates a danger that can immediately lead to death or serious injuries.
WARNING
Indicates a danger that can lead to death or serious injuries.
CAUTION
Indicates a danger that can lead to minor or moderate injuries.
ATTENTION
Indicates a danger that can lead to damage or destruction of the product.

1.3 Definitions used
Press-and-hold control
The operator only initiates door travel as long as the Up / Down button is pressed.

Press-and-release operation
After an impulse, the operator automatically travels to the end-of-travel position.

1.4 Symbols used
The instructions show how to fit an operator on a sectional door. Deviations for fitting with other doors are also shown.
All specified dimensions in the illustrated section are in [mm].
Icons

| Important note to prevent injury to persons and damage to property
---|---
| Permissible arrangement or activity
| Non-permissible arrangement or activity
| Check for ease of movement
| Check
| Indicates parts to be greased

1.5 Abbreviations used

Colour code for cables, single conductors, and components
According to IEC 60757:

WH| White| BK| Black
BN| Brown| BU| Blue
GN| Green| OG| Orange
YE| Yellow| RD/BU| Red /blue

1.6 Accessories

Article designations

SKS| Closing edge safety device
SE| Secured release (on the inside)
ASE| Secured release (on the outside)
GR| Maintenance release
HK| Crank handle

Safety instructions

ATTENTION:
IMPORTANT SAFETY INSTRUCTIONS.
FOR THE SAFETY OF PERSONS, IT IS IMPORTANT TO COMPLY WITH THE FOLLOWING INSTRUCTIONS. THESE INSTRUCTIONS MUST BE KEPT.

2.1 Intended use
This industrial door operator is designed for the operation of spring- compensated sectional doors in the industrial and commercial sectors. Note the manufacturer specifications regarding the door and operator combination. Potential hazards as outlined inDIN EN 13241 are avoided by construction and fitting according to our guidelines. Door systems that is located in a public area and which only have one protective device, such as a power limit, may only be operated under supervision.
Intended use also includes following all the notes provided in these instructions, and complying with the maintenance instructions and country- specific standards and safety regulations as well as the logbook.

2.2 Non-intended use
The operator may not be used with doors that are not counterbalanced or insufficiently counterbalanced.

2.3 Fitter qualification
Only correct fitting and maintenance in compliance with the instructions by a competent/specialist company or a competent person/specialist ensures safe and flawless operation of the system.
According to EN 12635, a specialist is a person with suitable training, specialist knowledge, and practical experience sufficient to correctly and safely fit, test, and maintain a door system.

2.4 Safety instructions for fitting, maintenance, repair, and dismantling

DANGER
Compensating springs are under high tension
▶ See warning in section 3.1

WARNING
The danger of injury due to insufficient inspection and maintenance
▶ See warning in section 5
The danger of injury due to unexpected door run
▶ See warning in section 5
The danger of injury during repairs and maintenance work
▶ See warning in section 5.1
The danger of injury due to insufficient stability during maintenance
See warning in section 5.1
Release
▶ See warning in sections 4.3, 5.2

Fitting, maintenance, repairs, and disassembly of the door system and the industrial door operator must be performed by a specialist.
▶ In the event of a failure of the industrial door operator, a specialist must be commissioned immediately for the inspection or repair work.

2.5 Safety instructions for fitting
The specialist carrying out the work must follow the prevailing national job safety rules and regulations and those governing the operation of electrical equipment. In the process, the relevant national guidelines must be observed. Potential hazards as outlined in EN 13241 will be prevented by the construction and fitting according to our specifications. After fitting is complete, the specialist must declare conformity in accordance with EN 13241 based on the area of application.

DANGER
Danger to life from the pull rope/hand pulley (chain or rope)
▶ See warning in sections 3.2, 3.3
Mains voltage
▶ See warning in section 3.14

WARNING
Unsuitable fixing material
▶ See warning in section 3.2
The danger of injury due to unwanted door travel
▶ See warning in section 3.2
The danger of injury due to insufficient stability during fitting
See warning in section 3.2
The danger of injury due to insufficient stability during maintenance
See warning in section 5.1
Removing the locking pins
▶ See warning in section 3.14

ATTENTION
Damage to the boom
▶ See warning in section 3.15

2.6 Safety instructions for installation
DANGER
Mains voltage
▶ See warning in section 3.14

ATTENTION
Faults in the system cables
▶ See warning in section 3.14

2.7 Safety instructions for initial start-up and for operation
DANGER
Deactivating the power limit
▶ See warning in section 4.1

WARNING
The danger of injury during door travel
▶ See warning in section 4.1
The danger of injury due to uncontrolled door travel in the Closed door direction in case of fracture of an existing counterbalance spring
▶ See warning in section 4.1
The danger of injury due to unexpected door run
▶ See warning in section 3.15

2.8 Tested safety equipment
The following functions or components, where available, meet cat. 2, PL “c” in accordance with EN ISO 13849-1:2008 and were constructed and tested accordingly:

• Internal power limit
• Tested safety equipment

If such properties are needed for other functions or components, this must be tested individually.

WARNING
The danger of injuries due to faulty safety equipment
▶ See warning in section  3.14

Fitting

ATTENTION:
IMPORTANT INSTRUCTIONS FOR SAFE FITTING.
FOLLOW ALL INSTRUCTIONS; INCORRECT FITTING CAN LEAD TO SERIOUS INJURIES.
The instructions show how to fit an operator on a sectional door. Deviations for fitting with other doors are also shown. All dimensions are in [mm].

3.1 Testing the door system

DANGER
Compensating springs are under high tension Serious injuries may occur while adjusting or loosening the compensating springs!
▶ For your own safety, only have a specialist conduct work on the compensating springs of the door and, if required, maintenance and repair work!
▶ Never try to replace, adjust, repair or reposition the compensating springs for the counterbalance of the door or the spring mountings yourself.
▶ In addition, check the entire door system (joints, door bearings, cables, springs and fastenings) for wear and possible damage.
▶ Check for the presence of rust, corrosion, and cracks.
A malfunction in the door system or incorrectly aligned doors can cause serious injuries!
▶ Do not use the door system if repair or adjustment work must be conducted!

The operator is not designed for the operation of sluggish doors. These doors are either difficult or impossible to open or close manually. The door must be in a flawless mechanical condition, as well as correctly balanced so that it can be easily operated by hand (EN 12604).
▶ Check whether the door can be opened and closed correctly.
▶ Lift the door by approx. one meter and let it go. The door should stay in this position and neither moves downward nor upward. If the door does move in either direction, there is a danger that the compensating springs/weights are not properly adjusted or are defective. In this case, increased wear and malfunctioning of the door system can be expected.
▶ The mechanical locking devices of the door that are not needed with an operator must be put out of operation (see section 3.4). This includes in particular any locking mechanisms connected with the door lock.

3.2 Installing the operator
WARNING
Unsuitable fixing material
Use of unsuitable fixing material may mean that the operator is insecurely attached and could come loose.
▶ The fitter must check the suitability of the provided fixing material (plugs) for use in the intended fitting location; other fixing material must be used if the provided fixing material is suitable for concrete (≥ B15/C12/15), but is not officially approved.

DANGER
Danger to life from the pull rope/hand pulley (chain or rope) A running rope may lead to strangulation.
▶ Remove the rope/hand pulley before fitting the operator.

WARNING
The danger of injury due to unwanted door travel
Incorrect fitting or handling of the operator may trigger unwanted door travel that may result in persons or objects being trapped.
▶ For your own safety, only have the product fitted by an approved specialist company!
▶ Comply with the applicable job safety rules and regulations during fitting work.
▶ Only carry out work on a completely fitted door and with the counterbalance spring tensioned.
▶ Follow all the instructions provided in this manual.

Incorrectly fitted control devices (e.g. buttons) may trigger unwanted door travel. Persons or objects may be trapped as a result.
▶ Install control devices at a height of at least 1.5 m (out of the reach of children).
▶ Fit permanently installed control devices (such as buttons, etc.) within sight of the door, but away from moving parts.

WARNING
The danger of injury due to insufficient stability during fitting Falls and severe injuries may occur if stability is poor during fitting of the operator (e.g. if the fitter is only standing on a ladder).
▶ Use stable equipment, such as a lifting platform or scaffold, when fitting the operator.

ATTENTION
Damage caused by dirt
Drilling dust and chippings can lead to malfunctions.
▶ Cover the operator during drilling work.

NOTICE

• Check the door travel during fitting; the rollers may need to be adjusted on sectional doors.
• When fitting a chain drive operator, use a suitable type of grease, e.g. copper paste, at the shaft connection points between the operator/axle, or axle/boom.
• A secured release (SE and ASE) is necessary for areas without a second entrance to prevent the possibility of being locked in or out (see SE and ASE instructions).

3.3 Removing the pull rope
DANGER
Danger to life from the pull rope/hand pulley (chain or rope) A running rope may lead to strangulation.
▶ Remove the rope/hand pulley before fitting the operator.

3.4 Securing or removing door locking devices
NOTICE
Completely remove all mechanical locking devices of the door that are not required for use with an operator. This includes in particular any locking mechanisms connected with the door lock.
▶ Remove the floor locking on the door (Figure 2).
▶ If the door is equipped with a shoot bolt, a limit switch unit for the “night lock” function must be retrofitted. To deactivate the shoot bolt, block it in the released position using the supplied spacer ring (Figure 3).
▶ Remove the full rotary latch (Figure 4).

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3.7 Alternative fitting position of the chain drive operator
Operator motor facing the inside of the door (fitting with limited space)
NOTICE
The travel distance is reduced by 100 mm with this fitting position.

3.8 Fitting the fitting bracket

3.9 Fitting the lintel joint

3.10 Fitting the boom

3.11 Connecting the door to the operator

3.12 Fastening the operator to the boom

3.13 Fitting junction boxes
3.13.1 Frame junction boxes
▶ If possible, fit the frame junction box on the same side as the control.
NOTICE
Always insert cables from the bottom or from the side.
If the wicket door contact on a door with wicket door is fitted opposite the control side, the frame junction box must also be fitted on the opposite side of the control.

3.13.2 Door leaf junction boxes
▶ Fit the door leaf junction boxes on the bottom edge of the door leaf.
For doors with wicket door (≥ 5500 mm):
▶ Fit the door leaf junction box with the plate holder directly on the reinforcement profile of the bottom section.
For doors with folding roller brackets:
▶ Fit the door leaf junction box with the plate holder directly above the folding bracket roller on the bottom section.

NOTICE
During installation, make sure that the cable is never guided from the top!
▶ Plug the ventilation hose into the Opto sensor and the door leaf junction box.

3.14 Electrical installation
This section describes the fitting and connection of further add-on parts.
For the electrical installation of circuits with dangerous voltages, observe the control instructions.

DANGER
Mains voltage
Contact with the mains voltage presents the danger of a deadly electric shock. For that reason, observe the following notes under all circumstances:
▶ Electrical connections may only be made by a qualified electrician.
▶ The on-site electrical installation must conform to the applicable safety regulations (230 V 1 AC, 50/60 Hz).
▶ Disconnect the system from the main supply and prevent it from being switched on again without authorization.

**WARNING**
The danger of injury due to incorrect installation of the operator could result in serious injury.
▶ The on-site electrical installation must conform to the applicable protective regulations.
▶ Electrical connections may only be made by a qualified electrician!
▶ Any further processing must ensure that the national regulations governing the operation and fitting of electrical equipment are complied with.

**WARNING
Removing the locking pins**
If the locking pins are not removed, the safety mechanisms cannot be actuated.
▶ Remove the locking pin of the cable slack device on both sides and, if present, of the spring safety device (see door instructions).

**WARNING**
The danger of injuries due to faulty safety equipment In case of an error, non-functional safety devices can result in injury.
▶ The person commissioning the system must check the function(s) of the safety device(s).
The system is only ready for operation after the function check.

ATTENTION
Damage due to incorrect electrical installation Incorrect installation could result in damage. For that reason, observe the following notes under all circumstances.
▶ External voltage on the connecting terminals of the operator adapter print will destroy the electronics.
▶ Never pull on the connecting cables of the electrical components, as this will destroy the electronics.
▶ Be sure to feed the system cables into the housing from below.
▶ Use blind plugs to close off unused connections.

ATTENTION
Faults in the system cables
Connection cables and system cables laid together can result in malfunctions.
▶ Duct the operator’s connection cables (24 V DC) in an installation system that is separate from the supply lines (230 V 1 AC).

NOTICE

• Wiring of Opto sensors for various protection categories: version IP 65.

3.14.1 Press-and-release operation with wicket door contact and night lock on the control side

3.14.2 Press-and-release operation with night lock on the control side and wicket door contact opposite the control side

3.15 Operator teach-in
▶ Switch to the control operating instructions

ATTENTION
Damage to the boom
Severe damage may occur to the boom if the link bracket of the roller chain is not coupled in the slide carriage and moves into the drive or pulley unit.
▶ Before teaching in the travel limits, check that the link bracket of the roller chain is coupled in the slide carriage.

3.16 Fitting the end stop
WARNING
The danger of injury due to unexpected door run
An unexpected door run may occur during fitting of the end stop if the door system is inadvertently actuated by a third person.
▶ Safeguard the door system against being switched on again without authorization.

▶ Perform at least three complete door cycles before fitting the Close end stop (Figure 16.1).
▶ Position the end stop in the boom in a way that allows the slide carriage to be right in front of it when the door is closed (Figure 16.2).

3.17 Handing over the operating instructions
▶ After completing fitting and installation, hand the fitting, operating, and maintenance instructions as well as the log book over to the operator of the door system.

Initial start-up

Initial start-up of the door system – especially the operator – includes:

• Checking the counterbalance of the door system (see door instructions)
• Switching on the energy supply
• Setting the operating parameters for the door system (control instructions)
• Checking the function of safety equipment
• Instructing operators and users

4.1 Operation
DANGER
Power limit adjustment
The power limit can be adjusted in this operator (see control instructions).
Adjustment of the power limit can lead to serious injuries and even death.
▶ Adjustment must be carried out by a specialist company. The liability of the manufacturer for damages due to the deactivated power limit is excluded.

WARNING

The danger of injury during door travel
If people or objects are in the area of the door during door travel, this can lead to injuries or damage.
▶ Children are not allowed to play near the door system.
▶ Make sure that no persons or objects are in the door’s area of travel.
▶ If the door system has only one safety device, only use the operator if you are in view of the door.
▶ Monitor the door travel until the door has reached the end-of travel position.
▶ Do not drive or walk through the door openings when the door is closing.
▶ Never stand under the open door.

WARNING
The danger of injury due to uncontrolled door travel in the Close direction in case of fracture of an existing counterbalance spring
Uncontrolled door travel in the Closed door direction occurs if, in case of a broken counterbalance spring, an insufficiently balanced door and a not completely closed door,
▶ a. the maintenance release WE or
▶ b. the secured release SE / ASE is actuated.
▶ For your safety, only release the door system when the door is closed.
▶ Never stand under the open door.
Door crashing is the result of manually actuating a door without a spring safety device and with a released operator (e.g. during maintenance) and subsequent fracture of the counterbalance spring.
▶ Manually actuate the door no longer than necessary and do not leave the door unattended until the operator is locked again.

ATTENTION
Gearbox wear or failure
If the power limit sensitivity has been set too low or it has been deactivated, the operator may not detect a fractured counterbalance spring. This will cause substantial gearbox wear or failure.
▶ Inspect the door system monthly if the power limit sensitivity has been set too low or it has been deactivated and have a fractured spring replaced immediately.

The operator is responsible for complying with the following regulations (without any claim to completeness):
These are listed in the enclosed log book.
4.2 Instructing users
▶ All persons using the door system must be shown how to operate the operator properly and safely.

4.3 Emergency operation equipment

ATTENTION
Use of the emergency operation equipment The door may only be operated via the emergency operation devices in case of a malfunction. Use of emergency operation devices over a longer period of time could lead to damage, rendering the warranty null and void.
▶ Only use the emergency operation equipment in case of power failure or repair work.

4.3.1 Emergency release
CAUTION
Release
There is a danger of injury and damage in the door’s area of travel.
▶ The release may only be actuated by instructed personnel when the door is closed; in doing so, the slide carriage must be relieved (see Figure 17). The door must also be secured against dropping.

Unlocking
▶ Pull the red cord knob (Figure 17.1).
NOTICE
Release is only possible when the carriage is in contact with the end stop.
Coupling
▶ Pull the green cord knob (Figure 17.2).
During the next door run, the chain lock automatically engages with the carriage.
Preventing the possibility of being locked out / in
▶ Lock the plunger on the slide carriage (Figure 17.3).
Alternatively, the secured release SE can be used with the external release ASE (Figure 17.4).
▶ Check the emergency release monthly for proper function.

Maintenance instructions

WARNING
The danger of injury due to insufficient inspection and maintenance Power- driven doors must be tested for safe condition by a specialist:

• Before initial start-up
• At least once a year
• At least every 6 months in case of more than 50 door operations per day (corresponds to approx. 10,000 operations)

Inadequate inspection and maintenance pose a danger of injury to persons and damage to property.
▶ Talk to your specialist company and arrange for the door to be regularly inspected and maintained.

WARNING
The danger of injury due to unexpected door run An unexpected door run may occur during inspection and maintenance work if the door system is inadvertently actuated by
a third person.
▶ Disconnect the door system from the power supply during inspection and maintenance work.
▶ Safeguard the door system against being switched on again without authorization.

A visual inspection may be carried out by the operator.
▶ Check all safety and protective functions monthly.
▶ Any malfunctions or defects must be rectified immediately by a specialist company.

5.1 Maintenance
WARNING
The danger of injury during repairs and maintenance work
A fault in the door system or an incorrectly aligned door can lead to serious injuries.
▶ Do not use the door system if repair or adjustment work must be conducted.

**WARNING**
The danger of injury due to insufficient stability
Falls and severe injuries may occur if stability is inadequate during maintenance of the operator (e.g. if the fitter is only standing on a ladder).
▶ Use stable equipment, such as a lifting platform or scaffold, during maintenance of the operator.

5.2 Maintenance release
CAUTION
Release
There is a danger of injury and damage in the door’s area of travel.
▶ The release may only be actuated by specialist personnel while the door is closed.
NOTICE
The maintenance release is not required if the secured release SE / ASE is installed.

5.3 Inspection instructions
Observe the inspection instructions for the door and
control.
5.3.1 Gearbox
The operator gearbox features life-long lubrication and is maintenance-free.
▶ Ensure that the output shaft and the drive shaft assemblies are always free of rust.
5.3.2 Operator
If the operator has an FC, it must be checked after 250,000 cycles
5.3.3 Connection elements
▶ Inspect all screws for corrosion, cracks, and a tight fit.

5.3.4 Secured release
▶ Check the secured release SE / ASE for function, ease of movement and condition.
5.3.5 Electrical lines and components
▶ Check (if applicable):
– Coiled cable for damages
– System cables for damages
– Wicket door contact, night lock and closing edge safety device for function
– Closing edge profile for function and tightness.
– Junction boxes for penetration of moisture.

Dismantling and disposal

6.1 Dismantling
Have a specialist dismantle the operator in the reverse order of these instructions.
6.2 Disposal
Have the operator disposed of by a specialist? Contact your specialist company for this purpose.

Warranty

For the warranty, the generally recognized terms and conditions or those agreed in the delivery contract apply. The warranty does not apply for damage resulting from insufficient knowledge of the provided operating instructions. Structural changes made without our prior approval, or improper installations carried out or initiated contrary to the fitting guidelines we have provided, shall also render the warranty null and void. Furthermore, we will assume no responsibility for the accidental or careless operation of the operator and accessories, nor for improper maintenance of the door and its counterbalance.

8 Excerpt from the manufacturer’s declaration
(as defined in EC/EU Machinery Directive 2006/42/EC according to Annex II, Part 1 A for a complete machine or Part 1 B for incorporation of an incomplete machine). This operator may only be fitted in combination with specifically approved door types. These door types can be found in the complete EC/ EU Declaration of Conformity in the provided log book. When combining this operator with a door, the fitter is considered a manufacturer of the complete machine. In this case, fitting may only be done by a fitting company, as only they have knowledge of the relevant safety regulations, valid directives, and standards, as well as the required testing and measuring devices. The appropriate manufacturer’s declaration can also be found in the provided log book.

Technical data

ITO 500 FU
HÖRMANN KG Verkaufsgesellschaft
Upholder Weg 94-98
33803 Steinhagen
Deutschland

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