ROGER BIONIK8 Automatic Barrier Brushless Instruction Manual

ROGER BIONIK8 Automatic Barrier Brushless

Specifications

• Product Name: BIONIK8 Automatic Barrier Brushless
• Model: IS194 Rev.08
• Power Supply: 36 Vdc
• Motor Power Supply: 2500
• Operating Cycles per Day: Super Intensive
• Grade of Protection: IP54
• Operating   Temperature: 24V up to 8 meters

Product Usage Instructions

Installation

1. Ensure the barrier is installed in private or public car parks, residential, commercial, or industrial areas.
2. Verify that the boom length does not exceed 8 meters for proper operation.
3. Securely fix the barrier with tie rods and screws provided in the package.

Operation

1. Connect the barrier to a 36V DC power supply.
2. Operate the barrier using the integrated control unit.
3. Use the key with the DIN cylinder for an optional emergency release system.

Maintenance

1. Regularly check the barrier for any physical damage or wear.
2. Keep the barrier clean and free from obstructions for smooth operation.
3. Ensure the operating temperature is within the specified range for optimal performance.

FAQ

Q: What is the maximum boom length supported by the BIONIK8 barrier?

A: The BIONIK8 barrier supports booms up to 8 meters in length.

Q: Can the barrier be used for purposes other than those specified?

A: No, the barrier should only be used for its expressly intended purpose to avoid any damage or risks.

Q: How should I connect the emergency battery to the barrier?

A: The emergency battery connection is optional and can be done using the key with the DIN cylinder provided.

Symbols

Intended use

• The BIONIK aut-rated barrier is specifically conceived for installations in private or public car parks, in residential, commercial, or industrial areas.
• This product may only be used for its expressly intended purpose. Any other usage is prohibited.
• ROGER TECHNOLOGY cannot be held directly or indirectly responsible for any damage resulting from incorrect, inappropriate, or unreasonable usage of this product.

Limits of use

• BIONIK8 barriers are suitable for VERY HEAVY DUTY operation and may be used with booms up to 8 meters in length.

Product Description

BI/008

• BIONIK BRUSHLESS 36V barrier for bars up to 4 meters, with on-board control unit, absolute encoder, complete with fixing base with tie rods and screws, and boom fixing flange

BI/008/115

• BIONIK brushless 36V barrier for bars up to 4 meters, with on-board control unit, absolute encoder, complete with fixing base with tie rods and screws, and boom fixing flange. For line voltages of 115V

Dimensions

Note: all measurements are expressed in mm unless otherwise indicated.

Package content

Technical characteristics

ABSOLUTE ENCODER DIGITAL

| ENCODER ASSOLUTO DIGITALE

ABSOLUTE ENCODER DIGITAL

Operating cycles per day (opening/closing – 24 hours no stop| 2500| 2500
Use frequency| SUPER INTENSIVE SUPER INTENSIVE| SUPER INTENSIVE SUPER INTENSIVE
Grade of protection| IP54| IP54
Operating temperature| |
Accessories power supply| 24V| 24V
Boom| fino a 8 meter up to 8 metres| fino a 8 meter up to 8 metres
Emergency battery| OPZIONALE

OPTIONAL

| OPZIONALE

OPTIONAL

Release system| A CHIAVE CON CILINDRO DIN KEY WITH DIN CYLINDER| A CHIAVE CON CILINDRO DIN KEY WITH DIN CYLINDER
Sound pressure during use| <70 dB(A)| <70 dB(A)
Control unit (integrated) 36 Vdc| CTRL| CTRL
Force to be applied to the mechanical| <1,6Nm| **** <1,6Nm

Internal test verified at nominal values with maximum boom size at an ambient temperature of +25°C. The value shown is NOT the maximum value

Typical installation

mechanical stop_
10| Release system
11| Key or keypad release switch

References and accessories

treatment and painted
**2|  | ** Aluminum boom support base, die-cast, with anti- corrosion treatment, painted

3

| **JNT/BA/128| ** BIONIK 8. Internal connection joint made of anodized aluminum.

4

| **BA/128/4| ** Boom L 4,1 m made of aluminum, with slot cover profiles and shockproof rubber
5|  | Zinc-coated steel boom fastening bracket
**6|  | ** Aluminum boom fixing cover, die-cast, with anti- corrosion treatment, painted
**7| | ** Head in die-cast aluminum with anti-corrosion treatment and painted, complete with diffuser in transparent polycarbonate and BI/BLED/8 LED lights
8| CTRL| Digital control unit for BI/008
9|  | ** Gate open/close mechanical stop
10|  | Steel springs fastening linkage lever
 | Code| Description
---|---|---
11| | Gear motor complete with Brushless motor and absolute encoder
12| SP/85/AS/02| 2 Ø85 springs for booms up to 8 m
13| | Corrosion-proof, painted steel inspection hatch
14| KT244| Galvanised base plate for barrier fastening
15| BAFS/01| Fixed end rest, non-adjustable, with rubber buffer
16| BAFS/03| Fixed end rest with rubber, non-adjustable, with holes for a latch chain and rubber buffer
17| BAFS/02| Fixed end rest with rubber, adjustable, telescopic with rubber buffer
18| BAFS/04| Fixed end rest with rubber, adjustable, telescopic with holes for a latch chain and rubber buffer
19| BAFS/05| Fixed end rest with rubber, adjustable, telescopic with rubber buffer and integrated magnet
20| KT231| Fixed-end rest fastening plate
21| BAMS/01| Hinged end rest for booms
22| BAMS/01/EXT| Extension for hinged end rest
23| BI/BAT/KIT| Emergency battery kit complete with battery charger and wiring (optional)
24| BI/BCHP| Battery charge board complete with wiring (optional)
25| KT239| DIN bar
26| KT242| Magnetic cable passage kit
27| ALED/8C| 8 m LED strip
28| R99/BASB20| Package of 20 refractive adhesive strips for the boom
29| BARK/02| Drop skirt in painted aluminum. L = 2 m
30| RS/GR2/100**| Lithium grease (EP LITIO)

ATTENTION! For the correct installation and use of the accessories refer to the respective instruction manuals

Installation

Preliminary checks

• Check that the material received is in good condition and suitable for the application.
• Check that the operating limits of the product are not exceeded.
• Check that the site chosen for installation meets the overall space requirements of the product and that there are no obstacles hindering open or close maneuvers.
• Check the concrete base for the barrier installation. The base must be cast under proper working practices, perfectly level, and clean.

Installing base plate

• The illustrations herein are indicative only. The space necessary for fastening the automation system and the accessories may vary depending on the overall dimensions of the installation.
• The installer is responsible for determining the most suitable solution.
• Excavate a foundation pit measuring 1,5m x 1m x 0,5 m and fill it with concrete reinforced with steel mesh.
• Fasten the 4 anchor ties to the plate (fig. 1). N.B.: the bottom nut must be tightened to the end of the thread on the screw so that the length Z is at least 40 mm.
• Sink the base plate with the anchors in the center of the foundation pit, so that the surface is flush with the concrete and perfectly level. The corrugated cable conduits must protrude by a few centimeters from the center of the plate (fig. 2).
  Installation on existing surfaces. Place the base plate on the surface and trace the positions of the fastener points. Drill the surface and fit 6 expansion anchor bolts (purchased separately).

Installing the barrier

• N.B.: the barrier is configured by default for installation on the right-hand side (viewed from the inspection hatch).
• Undo and remove the washers and nuts from the anchors on the base plate (fig. 3).
• Open the inspection hatch, turning the key clockwise 90° (fig. 4), and remove it.
• Place the cabinet on the plate. The anchors on the base plate must fit through the six slots.
• Fit the washers and nuts removed previously. Move the cabinet as necessary in the slots to adjust the position of the barrier correctly.
• Tighten the nuts securely (fig. 6).

Selecting the direction of the aperture

• BIONIK barriers are configured by default for installation on the right-hand side (seen from the inspection hatch side).
• Whenever corrective actions are carried out, pay the utmost attention when releasing, locking or moving the internal mechanical parts.
• These operations could be hazardous for the installer.

For left-hand installations:

• Unlock the barrier (see Chapter 20).
• Turn the linkage lever as shown in the figure.
• Move the mechanical stop.
• Lock the barrier (see chapter 20)
• BARRIER INSTALLED ON THE RIGHT (seen from the inspection hatch side) AND THE BOOM OPENING/CLOSURE GATE ON THE LEFT
• BARRIER INSTALLED ON THE LEFT (seen from the inspection hatch side) AND THE BOOM OPENING/CLOSURE GATE ON THE RIGHT

Boom installation

IMPORTANT: The BIONIK8 barrier is supplied with two 4.1 m booms (D1 and D2).

WARNING!

• Unlock the barrier (see Chapter 20).
• Turn the linkage lever into the position necessary for installing the boom horizontally.
• Lock the barrier.

D1 boom preparation (figure 8)

• to avoid damaging the surface of the components, it is recommended to place them on a stable and soft surface.
• Remove the plug Q1 and the end flange R1. These two parts will NOT be used again.
• Remove the led cover N1 and shorten it by 285 mm from the side where it is fastened to the boom support.
• Remove the protective rubber P1 and shorten it by 285 mm from the side where it is fastened to the boom support.
• Cut the excessive protective rubber at the opposite end as well.

D2 boom preparation

• Remove the plug Q2 and the end flange R2.
• Remove the led cover N2 and the protective rubber P2. CAUTION: these two components should NOT be cut.

Installing and adjusting the spring

The booms are understood as complete with shock-resistant rubber and LED strips.

• The adjustable fixed-end rest with integrated magnet BAFS/05 must be used
• The adjustable fixed-end rest with integrated magnet BAFS/05 must be used
• The adjustable fixed-end rest with integrated magnet BAFS/05 must be used
• WARNING! For booms of 4 m or more, it is mandatory to use the BAFS fixed end rest or the BAMS hinged end rest.
• ATTENTION! Images are purely indicative, for correct installation and use of the accessories refer to the respective instruction manuals.

Installation and adjustment of the balancing unit

• The balancing unit is composed of a linkage lever, a slider [CU], and a spring unit.
• The linkage lever has two 4 mm pitch-toothed windows, on which the [CU] slide will be fit.
• On one of the holes on the slider [CU] the SPRING SET SP/85/AS/02 will be fit.
• The supplied sliders are of two types CU1 and CU2 and can be distinguished by the identifying marks (see * and **).
• The two types of sliders allow millimeter adjustment of the spring travel, since the spacing between the holes is different (26-24 mm), see details in fig. 14 and 15.
• Fit the most appropriate slider CU for a correct balancing of the boom.

Slider selection

• The correct position of the slider is determined by the boom weight: the heavier the boom is (weight determined by the totality of the accessories installed), the more to the outside the slider should be installed.
• Reversing the insertion direction of the slider, rotating it by 180°, the hole spacing value is modified concerning the linkage lever center, see fig. 14 and 15 (e.g. 135, 136, 137, 138 mm values).
• To decrease the travel (extension) of the spring, move the slider CU inward by one pitch in the linkage lever and check the tensioning of the springs.

Spring unit installation

1. Unlock the barrier (see Chapter 20) and move the boom into the completely open vertical position.
2. Fasten the spring unit SP/85/AS/02 to the linkage lever using the screws included (fig. 16), according to the opening direction and in the position that allows the correct movement of the barrier. The internal roller bearing [S] is composed of 3 modular elements which, if incorrectly assembled, inhibit the correct operation of the barrier.
   • CAUTION: using the slider hole that is the farthest from the linkage lever center, during barrier operation, the springs will be more tensioned, while, vice versa, when using the slider hole that is the closest to the linkage lever center, the springs will be less tensioned.
3. Fasten the springs to the fixed structure (fig. 17) on the steel crossbar of the barrier, using the screws included. The heavier the boom is (the totality of the accessories installed), the more to the outside the springs should be installed (hole A).
   • Check the correct operation of the balancing system.
   • Lift the boom manually to an angle of 45° and let go. If the boom rises or falls, try another position of the slider CU1. Whenever this is not sufficient, the slider can be rotated by 180°, to change the 2 mm hole pitch (fig. 14 – values 136 and 138).
4. To obtain millimeter precision, replace CU1 with the CU2 slider included (fig. 15 – values 135 and 137).
5. Grease the points indicated in fig. 16 and 17 with LITHIUM grease (EP LITHIUM). Available upon request, article RS/GR2/100: 100 g can of lithium grease.

Spring adjusting

1. Adjust the spring tensioning by loosening the nuts [A] as indicated in Fig. 18.
2. By moving upward the fastening crossbar [B], the spring tensioning increases; vice versa, by moving it downward, the tensioning decreases.
3. Lift the boom manually to an angle of 45° and let go. If the boom rises, reduce the spring tension. If the boom falls, increase the spring tension (fig. 19).
4. Once the spring tension is correct, tighten the lock nuts securely.

• To protect the spring from moisture and internal condensation, it is good practice to brush the spring with a thin layer of grease, which will prevent rusting.
• It is good practice to silicon the cable passage hole at the base of the barrier.

Adjusting the mechanical stop

• Figure 20 shows the mechanical stop on a barrier installed on the LEFT-hand side.
• For barriers installed on the RIGHT, perform the mirror images of the procedures illustrated.
• Unlock the barrier (see Chapter 20).
• Set the completely open [AP] and completely closed [CH] positions by adjusting the relative mechanical stops.
• Lock the barrier (see Chapter 20).

Installing the lock release system

• The lock release system is already installed in the factory on one of the two sides of the barrier. If it is necessary to install the system on the opposite side (compared to springs):
• Open the inspection hatch.
• Remove the screws fastening the plastic cover [A].
• Remove the escutcheon plate [B] of the lock release system, prising the lateral clips open to detach.
• Undo the two self-tapping screws [C] and remove the aluminum front panel [D].
• Undo the four M5 nuts [E].
• Push the steel connector [F] outwards to compress the spring and rotate by 45°.
• Detach the lock release system and install it on the opposite side, taking care not to damage the safety cable.
• N. B.: two colored caps (red and green) are fitted to check that the lock release system is installed correctly, regardless of which side it is fitted on.
• When the barrier is locked, the green cap must face toward the inspection hatch (installer view).
• If not, the lock release system is installed incorrectly.
• Tighten the nuts [E].
• Fit the aluminum front panel [D] and fasten it with the screws [C].
• Fasten the escutcheon plate [B] on the lock release system.
• Fit the plastic cover [A] on the opposite side.

Connecting photocells

• G90/F4ES photocells may be installed on both sides of the barrier at two different heights: (50 cm or 100 cm).
• Disconnect from mains electricity and battery power (if applicable).
• Open the inspection hatch, turning the key clockwise by 90°.
• Undo the four screws fastening the head.
• Remove the head after disconnecting the flashing light cables.
• Open the cover of the CTRL control unit.
• Undo the two screws fastening the plastic cover of the photocell housing from the inside.
• Fasten the G90/F4ES photocells to the barrier.
• Route the connector cables upwards, taking care not to interfere with the movements of the automation system, and push them through one of the openings on the control unit box.
• Connect the photocell cables to the specific terminals as indicated in the installation manual for the CTRL controller.
• See the CTRL control unit manual for instructions on setting the photocells.
• Close the control unit cover correctly, ensuring that it is watertight.
• Refit the barrier head.
• Close the inspection hatch, turning the key anticlockwise by 90°.
• Tighten the four screws to the head.

Electrical connections

• All electrical connections must be made with the unit disconnected from mains power and, if applicable, battery power. See the controller manual for instructions on making connections and programming CTRL.
• Before connecting to electrical power, ensure that the main power specifications on the identification plate match the main power supply used.
• A switch or an omnipolar cut-off switch with a contact opening of at least 3 mm must be installed on the main power line.
• Ensure that an adequate residual current circuit breaker and a suitable overcurrent cut-out are installed ahead of the electrical installation.
• Use a 3×2.5 mm2 double insulated cable for the main power line.
• Feed the cable on the left-hand side of the barrier through the rubber cable grommet on the left-hand side of the controller casing and connect it to the terminals L (brown), N (blue), and (yellow/green) inside the automation unit.
• Fasten the power cable with the cable grips included.
• At least 50 mm of the connector cable conduit must protrude from the holes in the base plate and into the automation unit.
• Ensure that there are no sharp edges that could damage the power cable.

Installing the battery kit (optional)

1. Disconnect the mains power.
2. Unscrew the screws [Z] and remove the head [A] (if applicable).
3. Lift the cable grommet [B] and disconnect the connector [C].
4. Open the transparent control unit cover [D].
5. Switch the control unit switch to the OFF position [E].
6. Lift the control unit and insert the batteries in their housing [F].
7. Connect the red, black, and blue wires to the batteries (see detailed view).
8. Connect the batteries to the +BATTERY terminal (red wire) and the -BATTERY terminal (black wire).
9. Insert the battery charge board BI/BCHP in the plug-in connector [G].
10. Reposition the control unit.
11. Switch the control unit switch to the ON position [E].
12. Reposition the transparent control unit cover [D].
13. Reconnect the connector [C] and close the cable grommet [B].
14. Close the head [A] and tighten the front screws [Z].
15. Reconnect the mains power.

Installing the BI/BLED/8 LED flashing light

In case of replacement:

1. Disconnect the mains and battery power supplies (if applicable).
2. Unscrew the screws [Z] that fasten the head [A] to the barrier.
3. Lift the cable grommet [C].
4. Disconnect the connector [B].
5. Remove and overturn the head [A].
6. Remove the BI/BLED/8 flashing lamp unit [D] from the diffuser.
7. Insert the new LED circuit in the diffuser, paying attention to the installation direction (fig. 26).
8. Insert the connector [B] in the LIGHT terminal of the control unit.
9. Refer to the control unit manual CTRL for the flashing lamp unit settings.
10. Fasten the cable grommet [C], making sure it is positioned correctly.
11. Reposition the head [A] on the barrier.
12. Tighten the fastening screws [Z].
13. Reconnect the mains and battery power supplies (if applicable).

Maintenance

• N.B.: Only use original spare parts when repairing or replacing products.
• The installer must provide the user with complete instructions for using the motorized door or gate in automatic, manual, and emergency modes, and must hand the operating instructions to the user of the installation upon completion.
• The installer must compile the maintenance log book, in which all scheduled and unscheduled maintenance operations performed must be indicated.
• The installation must be subject to regular maintenance. We recommend servicing at least once every 6 months.
• Disconnect from mains electricity and from battery power (if applicable) to avoid the risk of accident or injury.
• Check the tightness of all the fastener screws and nuts.
• Clean the photocell lenses with a cloth moistened slightly with water. Do not use solvents or other chemical products, as these may damage the electronic components.
• Clean and lubricate the pivot points with lithium-based grease (EP LITIO).
• Check the electrical connections.
• Check that the manual lock release system works.
• Check that the boom is balanced correctly.
• Check that there are now plants within the radius of action of the boom which could interfere with the photocells or with the movements of the boom itself. Reconnect to mains power.
• Check that the safety devices and all the control functions work correctly.
• Check that the obstacle detection function works correctly.
• Check that there is no risk of the boom accidentally lifting persons or objects.
• Check that the force limiting function prevents potentially dangerous situations in compliance with standard EN 12445.

Release and lock procedure

• Whenever corrective actions are carried out, pay the utmost attention when releasing, locking or moving the internal mechanical parts. These operations could be hazardous for the installer.
• In some situations, such as in the event of a power outage or scheduled or extraordinary maintenance, it is necessary to release the automation.
• The operation of the release of the automation must be carried out when the boom is stopped in the closed position (horizontal).
• Moreover, ensure that at the time of release, no person, animal, item, or vehicle is passing by or stopped within range of automation.

RELEASE AND MANUAL OPERATION

• Insert the key included into the lock and turn it anticlockwise by 360° making 2 complete turns, as indicated in fig. 1.
• Move the boom manually.

RESTORING AUTOMATIC OPERATION

• To lock the barrier again, turn the key clockwise by 360° making 2 complete turns, as indicated in Fig. 2.

Declaration of conformity

• I the undersigned, as acting legal representative of the manufacturer: Roger Technology – Via Botticelli 8, 31021 Bonisiolo di Mogliano V.to (TV) hereby DECLARE that the appliance described hereafter:
• Description: Automatic barrier
• Model: BIONIK8 serie

Is conformant with the legal requisites of the following directives:

• 2006/42/CE (Machinery Directive) and subsequent amendments;
• 2014/53/UE (RED Directive);
• 2011/65/UE (RoHS Directive) and subsequent amendments; and that all the standards and/or technical requirements indicated as follows have been applied:
• EN 61000-6-3; EN 61000-6-2; EN 60335-1
• The last two figures of the year in which marking was applied 18.
• Place: Mogliano V.to Date: 01-10-2018

Release and lock procedure

• Whenever corrective actions are carried out, pay the utmost attention when releasing, locking or moving the internal mechanical parts. These operations could be hazardous for the installer.
• In some situations, such as in the event of a power outage or scheduled or extraordinary maintenance, it is necessary to release the automation.
• The operation of the release of the automation must be carried out when the boom is stopped in the closed position (horizontal).
• Moreover, ensure that at the time of release, no person, animal, item, or vehicle is passing by or stopped within range of automation.

RELEASE AND MANUAL OPERATION

• Insert the key included into the lock and turn it anticlockwise by 360° making 2 complete turns, as indicated in fig. 1.
• Move the boom manually.

RESTORING AUTOMATIC OPERATION

• To lock the barrier again, turn the key clockwise by 360° making 2 complete turns, as indicated in Fig. 2.

BI/008

• BIONIK BRUSHLESS 36V barrier for bars up to 4 meters, with on-board control unit, absolute encoder, complete with fixing base with tie rods and screws, and boom fixing flange

BI/008/115

• BIONIK brushless 36V barrier for bars up to 4 meters, with on-board control unit, absolute encoder, complete with fixing base with tie rods and screws, and boom fixing flange. For line voltages of 115V
• The sound pressure during use is less than 70 dB(A).
• ROGER TECHNOLOGY Via S. Botticelli 8
• 31021 Bonisiolo di Mogliano Veneto (TV
• ITALIA P.IVA 01612340263
• Tel. +39 041.5937023
• Fax. +39 041.5937024
• info@rogertechnology.IT
• www.rogertechnology.com

Documents / Resources

| ROGER BIONIK8 Automatic Barrier Brushless [pdf] Instruction Manual
BI-008, BI-008-115, BIONIK8 Automatic Barrier Brushless, BIONIK8, Automatic Barrier Brushless, Barrier Brushless
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References

• Roger Technology - Automazioni in movimento

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