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USER MANUAL G 501

1. Screw fastenings Middle brachets Cap rails Guide rails Carriages Drive head fastening Tension Strength wear Strength screw connections corrosion Strength screw connections corrosion Strength screw connections corrosion Strength screw connections corrosion Strength screw connections corrosion Strength screw connections corrosion Corrosion Corrosion Strength wear Strength of the screw connection Housing cover Power networh cable Cables of accessory Cables of accessory Accessories Deflection roller unit Firm seating Damage firm seating of the plug Damage Firm seating of the terminals screws Firm seating damage Wear bearing corrosion Crown gear Wear Chain wheel Wear bearing Wear 12 2 CHECK OBSTACLE DETECTION FORCE CUT OFF The function of the automatic force cut off of the garage door drive is established by simple cheching In the direction opening Close door Load the door leaf in the area of the middle of the door with a mass of 20 hg for example a buchet with sand in it Start drive in the direction Open the drive must stop immediately error Fl6 is signalised In the direction closing Open door Place the test body for example a square timber with a height of 5O mm in the middle of the door under the door leaf on the floor start drive in the direction Close the drive must stop immediately upon arrival at the test body and free up the test body rever
2. number of parking spaces 8 Max openings open and close per day 16 Door size 10 Max weight 140 Max door area up to in m 12 Minimum installation height in mm 35 Length in mm 3300 Temperature range in C 2O C to 5O Mains connection 230 V Protection IP2O Stand by consumption in W ca O 3 12O 19 1200 18 180 24 V direct current geared motor 15 30 50 170 16 35 3300 20 to 5O 230 V IP20 0 3 Details given for the version of the device with toothed belt and a standard rail length of 3 000 mm 17 DECLARATION OF INCORPORATION Translation of the copy of the original EC declaration of incor poration for incomplete partial machines according to EC RL 2006 42 EG Annex IITA The manufacturer BERNAL Torantriebe GmbH Industriepark Sandwiesen D 72793 Pfullingen GERMANY of the incomplete partial machine Garage door drive G 501 hereby declares for the above mentioned product the essential health and safety requirements in relation to machi ne directive 2006 42 EC were used and observed The following harmonised standards or international and natio nal standards are used DIN EN ISO 13849 1 2008 12 Part 1 General design principles EN 12453 2005 05 EN 12445 2001 O1 DIN 13241 1 2004 04 EN 60335 1 2007 2 Part I General requirements EN 60335 95 2005 11 the safety objectives of the EMC directive 2004 108 EC ac cording to annex I no 1510 and 1 5
3. oned again when a secure condition was established A written inspection report must be completed for checking session This should be Rept with the inspection book During checking servicing or repair work it is necessary for va lid European and national standards as well as work protection and accident prevention regulations to be observed in their res pectively current version Your gualified specialised company 39 40 ALI DETAILS OF THE OPERATING COMPANY Owner operating company From to Company designation Name Street Postal code place Location Designation of the plant Street No Postal code place IN THE CASE OF A CHANGE IN OWNER OPERATING COMPANY Owner operating company 2 From to Company designation Name Street No Postal code place Location 2 Designation of the plant Street No Postal code place Owner operating company 3 From to Company designation Name Street No Postal code place Location 3 Designation of the plant Street No Postal code place AL2 SPECIFICATION MACHINE DATA Model designation Serial No Order No Order No Manufacturer Assembly company Date of commissioning The machine consists of the garage door Model designation Weight of door leaf Spring tension Serial No Manufacturer kg Width cm Height __________cm Fitting type turns Order No as
4. 11 of the machine directive 2006 42 EC were observed the safety objectives of the EMC directive 2006 95 EC accor ding to annex no 1 5 1 of the machine directive 2006 42 EC were observed serial number order number year of construction Adhesive sticker Type plate Safety of machines safety related parts of control systems Safety in use of power operated doors requirements Safety in use of power operated doors test procedures Doors product standard Part I Products without any fire protection and smohe protection properties Safety of household and similar electrical appliances Safety of household and similar electrical appliances Part 2 95 Special requirements for drives for garage doors with vertical movement for use in a residential area DIN EN 55014 1 2010 02 Electromagnetic compatibility requirements for household appliances electric tools and similar apparatus Part 1 Interference emission DIN EN 55014 2 2009 06 Electromagnetic compatibility requirements for household appliances electric tools and similar apparatus Part 2 Resistance to interference DIN EN 55016 2 1 2006 05 Requirements upon devices and installations as well as establishment of processes for measurement of high frequency interference emission radio interferences and resistance to interference Part 2 1 A process for measurement of high frequency interference emission radio interferences and resistance
5. HWC web service software required For purely private use or little use 25 of the maximum va lues for max cycles day max number of parhing places see Technical Data we recommend that the components listed above are replaced once every 10 years Toothed belt D DO D O3 or chain C OO C O2 Deflection roller unit F O1 Chain wheel 4 or crown gear 0 04 Gear motor 04 Shaft adapter 3 33 34 BERNAL TORANTRIEBE 242 221 222 232 12 1 INSPECTION SPECIFICATIONS Inspection point to chech for Force shut off Force shut off Safety elements photocells safety edges Emergency Stop Caution signalling lights Emergency release Emergency release Warning signs Type plate s Product documentation Control elements Function according to the description Values and times Function according to the description Function according to the description Function according to the description Strength wear routing Presence recognizability legibility Presence legibility Availability completeness Function according to the description 12 INSPECTION We recommend general cheching according to cheching in spection specifications and the inspection book as well as the annual inspection by a competent person also in the area of use according to EN 60335 2 95 Chain toothed belt Chain toothed belt Suspension elements Lintel securing fittings Push rod Door fittings
6. NOT continued possibly after a set prewarning time various door stati explicitly during the prewarning time are not recorded here the control unit generally returns here into a safe status in order to avoid any unexpected functions if an operating command was either triggered unintentionally or also by a second user An example In the operating mode automatic closing and the end position Door Open the hold open time has expired the prewarning time of the caution light is running an operating command ventilati on or Start leads to a reset of the hold open time which means the preset hold open time begins to run again 30 10 1 ERROR MESSAGES The garage door drive documents various events and reports these on Faults which are still present after Reset see table below must be checked by a qualified technician and removed repaired Error signalling on a device without a display Acceptance testing of the drive hood is essential for gaining 10 OPERATING FAULTS The red LED F lights up the multi segment display of the con Error signalling on a device with a display access to the control board Figure 35 the covers on the 230 V AC area of the control board see Figure 40 should ne ver be removed Error codes CODE DESIGNATION Overvoltage on the power supply network FOI Safety edge or photocell FO2 Stop triggered FO3 Photocell defective or a short circuit on th
7. Yes Yes LED white Integrated lighting LED2 No Yes LED white Integrated lighting LED3 No Yes LED white Integrated lighting LED4 Yes Yes LED white Integrated lighting I PROFESSIONAL EXTENSIONS 4 2 START BUTTONS Only command devices with a press button function impulse signal may be connected Continuous signals for example connection of a switch instead of a button lead to blocking of all other control commands Voltage free closer contacts NO and any number of control elements with a press button function for example a key ope rated push button can be connected to the START terminals Connect up a number of control elements in parallel Triggering of a Start command leads to Start or to Stop while the door is moving 2x0 250 NY 4 4 CONTACT SAFETY EDGE Recognition of the contact safety edge must be activa ted in the menu b 5 to 1 Ohmic contact safety edges 8 2 RQ can be connected to the terminals L and LS When using a number of safety edges up to 3 through switch strips can be attached with an end safety edge in series Use of a safety edge together with photocells see 4 5 or 4 6 4 3 STOP WICKET DOOR CONTACT The jumper installed at the works should be removed when using the connection Voltage free opener contacts NC and any number of Emer gency Stop elements or safety eguipment can be connected to the NOT terminals Connect up a number of control elements
8. ceiling must have an ade quate strength to receive the garage door drive The fastening materials screw dowels must be adapted according to the substrate at the local conditions and building regulations BERNAL TORANTRIEBE 2 3 4 ELECTRICAL INSTALLATION I Danger of injury to persons and damage to equipment due to receiving an electric shock I Danger of malfunctions occurring due incorrect installation A protective grounded contact socket is essential in the area 50 cm behind the drive head to provide power to the device A mains voltage of 230 V AC 15 50 60 Hz is necessary for perfect functioning of the device On site electrical installation connection or repair work on 230 V eguipment may only be done by trained electricians The power plug must be taken out and secured against plugging in again before performing any work on the garage door drive or door Acceptance testing of the drive hood is essential for performing the following activities Figure 35 Some areas of the control board carry 230 V AC the protective covers of the 230 V AC area of the control board Figure 40 must not be removed The drive hood should be put in place again immediately after com pletion of the activities and fixed firmly in place 1 Connection of accessories 2 Exchange of the control unit gear motor transformer Further activities are necessary after acceptance testing of the drive hood Figure 35 as wel
9. device and under the condi tion of normal use of a maximum of 10 door actuations per day Control system electronics transformer rail system 2 We will remove any deficit on the device for the period of the warranty which can be shown to be due to a material or manu facturing fault on one of the components encompassed by the warranty We undertake according to our discretion to either replace such a deficient device free of charge with a deficit free device or to repair it or to reimburse the reduction in value Re placed parts are our property 3 There is no possibility to mahe a claim under warranty for consumables e g fuses batteries illuminants The warranty is not extended if a claim is made under warranty The warran ty period is for 6 months for replacement and improvements made at least however the current warranty period or the legal minimum periods 4 The right to mahe a claim under warranty is only valid for for the country in which the device was bought The goods must have come over the sales channel prescribed by us The right to mahe a claim under warranty only exists for damage on the device itself resulting from faults which can be shown to be due 15 WARRANTY CONDITIONS to a material or manufacturing fault on one of the components encompassed by the warranty Reimbursement of costs for re moval and installation cheching of respective parts dispatch as well as demands for loss of earnings and compensa
10. hand transmitters Activate programming and enter menu C 3 Enter Delete all hand transmitters Confirm Position Delete all hand transmitters with ENTER programmed channels on all programmed radio hand trans mitters will be deleted irrevocably Finally leave the programming screen occurs within about 60 sec if there is no action the garage door drive moves bach au tomatically into operational readiness 6 3 Replace the battery in radio hand transmitter Loosen the screw S using a suitable tool First remove the bottom section of the housing A at the lower end and then the upper end Remove the battery B from the holder C and replace it while noting the polarity by a new battery of the type LRI alternative designations Lady MN9100 N Place the bottom section of the housing at the upper end en gage the snap in nose D and then at the lower end and secure with a screw S Note the contents of the section Disposal 25 26 BERNAL TORANTRIEBE I PROFESSIONAL EXTENSIONS 7 PROGRAMME DRIVE FUNCTIONS 2 3 1 2 3 2 2 3 5 2 3 6 2 3 7 71 SETUP FORCE menu Setup ofthe force cut off can be adapted in 9 stages to the gate see programming manual The function automatic obstacle detection force cut off must be checked after every manual change to the force setup A manual change to the force setup may only be performed with a measuring check according
11. permissible ifthe machine is not fitted out with additional safety equipment The area of movement of the machine may only be entered on foot or driven into when the machine has come completely to a standstill The machine should be stopped immediately if there are persons or objects in the area of movement of the machine No persons should be standing around under the opened door and there must not be any objects placed there When driving into the door area the lowest parts of the drive in particular the cable Bowden cable on the emergency release system should be observed in relation to the height of the ve hicle and any attached accessories roof luggage rack IF any deficits are discovered during operation the machine should be taken out of action totally shut down and repaired by a professional fitter before re commissioning The machine may only be commissioned again when a secure condition was established 2 4 2 CHECKING I General danger of injury to persons and damage to equipment IF the mechanical components of the door are defective actu ation of emergency release of the drive can lead to immediate dropping down of the door One must not reach into unsecured moving parts of the machi ne while cheching the machine The power plug must be tahen out and secured against plug ging in again before mahing any manual chechs of the strength of the components or screw connections or for corrosion or wear The danger ar
12. plug the gara ge door drive executes a self test for about 5 seconds For the version of the device without a display the set up assis tant starts the menu autonomously with menu point P Set ting force distance For the version of the device with a display 501 the request is made to select the language Then the set up assistant starts the menu autonomously with menu point Setting force distance Set up for repeating after changes have been made to the ma chine travel paths and force curves are already programmed in Activate programming and enter menu P 5 3 DOOR TYPE Only for use of the drive on swing doors which open outwards Figure 3 e the type of drive must be setup the direction of rotation of the drive is in the opposite direction here Activate door type swing door before set up is begun with run UP An additional adaptation of difficult movement cycles or force cyc les is possible after set up via Soft start stop see 8 2 5 4 PROGRAMME RUNWAYS Set up started with UP Control the door through ted pressing of the button into the end position Door Open Do not move into the mechanical limit of the door mechanism in the process Resetting can be achieved using DOWN if necessary Store the desired position Door Open Set up changes over to Run DOWN Control the door through repeated pressing of the button into the end position Door C
13. position Ventilation leads in operating mode Pulse repetition to Closing Opening Stop Stop Stop Opening Closing to the ventilation position Opening to the ventilation position None opening is continued leads in operating mode Automatic closing to Reset hold open time to the beginning Opening None opening is continued Stop Stop Opening Hold open time Opening Reset hold open time to the beginning Opening to the ventilation position None opening is continued Stop and after the renewed operating command Closing Stop Closing None START is ignored None START is ignored None opening is continued Stop reversing None START is ignored None START was ignored None START was ignored None opening is continued Stop reversing None START was ignored Stop Stop reversing None None Stop Stop None Stop Opening Hold open time Closing None START automatic closing was ignored None START automatic closing was ignored None opening is continued Stop reversing after Door Open None START automatic closing was ignored None START automatic closing was ignored None START automatic closing was ignored None opening is continued Stop reversing after Door Open None START automatic closing was ignored Stop Stop reversing after Door Open None None automatic closing is NOT continued Stop Stop None automatic closing is
14. soft drive runs jerkily Motor sensor error acc to the error code Path traversed by the door not accepted during set up Photocells safety edge out of function BERNAL TORANTRIEBE CAUSE No power supply network voltage Internal fine fuse defective Transformer defective Control board defective Motor gearbox defective Fuses activated in menu b4 b5 but not connected or wrongly connected Safety equipment active Cable connection of safety device defective Bridge jumper on the NOT terminal missing Continuous signal to the START connection Button or control element defective Cable connections defective loose Transmitter not programmed Interference experienced during programming Transmitter battery empty or installed wrongly Transmitter defective External receiver on HW ERW defective or not plugged in properly not for the original radio system B W AY Antenna missing wrong antenna e Interference while programming Restriction of the range due to local conditions Change in the door mechanics An obstacle in the path traversed by the door Door too heavy Changing the door mechanics through installation of the drive Installation of the drive outside the middle with an excessively high slope etc The push rod angle is too high Door too stiff Change in the door mechanics An obstacle in the path traversed by the door Set up operation programming run Control system defective Motor or gearbox defect
15. the copyright law is prohibited 61 BERNAL GmbH Industriepark Sandwiesen 72793 Pfullingen Germany Phone 49 0 7121 707 240 Fax 49 0 7121 707 225 E Mail info bernal de Internet www bernal de STAMP LOGO DEALER BERNAL GERMANY 1952
16. the obstacle Repeat the programming run with an obstacle Then check again in normal operation mode Shut down the machine have the door repaired by a qualified technician Replace the gear motor Check replace if necessary Check replace if necessary Tension attach chain dampener if necessary Degrease completely and clean Check replace if necessary Ensure good ventilation Seal Move the drive upwards Deactivate the automatic closing Check the mechanical function strength of the cable connections as well as access to the operating elements Deactivate set prewarning times to minimum Check the cable plug Check replace the motor cable if necessary Replace the motor Repeat for a longer or shorter path traversed by the door Activate b5 11 MAINTENANCE 2 3 1 2 3 2 2 3 5 2 3 6 237 The garage door drive is maintenance free except for the drive chain Chains should be slightly lubricated once a year using a suitable agent Remove excess lubricant immediately Toothed belts should never be lubricated If the device gets dirty clean it dry if necessary using a vacuum cleaner The chechs which should be made at regular intervals to main tain operating safety are shown in the chapter Cheching 11 2 OVERVIEW OF PARTS PARTS Components of the garage door drive which are subject to me chanical wear should be replaced by a professional fitter every 80 000 operating cycles HWC and
17. to EN 12445 by an expert in the machine Any change to the force setup must be documen ted in the inspection book Changing the closing force adjustment can lead to personal in jury Therefore increasing the clamping force may only be perfor med by a competent person After adjustment compliance with the normative values with suitable measuring device must be demonstrated and documented 7 2 TIME TILL AUTOMATIC CLOSING menu A Definition The time period which expires between stop in the end position Door Up and the automatic closing of the door The hold open time can be set up in 5 stages 10 sec to 240 sec The function is only available in the menu if the automatic clo sing is switched in menu b 3 active 7 3 WARNING TIME CAUTION LIGHT menu U Definition A delay which occurs between the start command and the motor start in which certainly a connected caution light and or the integral drive light pre flashes The prewarning time can be set up in various stages with separate times for delay in the opening or closing direction The function is only available in the menu if the function of the caution light is switched in menu b 6 active the function can optionally be released through appropriate selection in menu b 7 for the connection external light or the integral drive light or both options see 4 7 1 7 4 LIGHT menu L Definition Regulates the afterglow time of the integral drive light
18. to interference measurement of interference emission transmitted by lines DIN EN 55016 2 3 2007 08 Requirements upon devices and installations as well as establishment of processes for measurement of high frequency interference emission radio interferences and resistance to interference Part 2 3 A process for measurement of high frequency interference emission radio interferences and resistance to interference measurement of the radiated interference emission DIN EN 61000 4 3 2008 03 Electromagnetic Compatibility EMC Part 4 3 Cheching and measuring processes cheching the resistance to interference from high frequency electromagnetic fields DIN EN 61000 4 6 2008 04 Electromagnetic Compatibility EMC Part 4 6 Checking and measuring processes resistance to interference from interference sources transmitted by lines induced by high frequency fields DIN EN 61000 3 2 2005 09 DIN EN 61000 3 3 2002 05 Electromagnetic Compatibility EMC Part 3 2 Limit values limit values for harmonic currents Electromagnetic Compatibility EMC Part 3 3 Limit values limitation of changes in voltage fluctuations in voltage and flicRer in public low voltage power supply systems for devices with a rated current of lt 16 A per conductor which are not subject to any conditional connection DIN EN 61000 4 13 2003 02 Electromagnetic Compatibility EMC cheching and measuring processes cheching the resistance to inte
19. to the beginning of the list are shown dotted IF there are various options to select from then it is suggested using the striped buttons A and B to select the desired option 4 The request to scroll on to the next or the last menu point is in as far as it is not executed in individual steps shown with the pictograms 5 or 6 IF a menu point which offers various values or options for se tup is opened then the current setup always has a blach bach ground 7 Various screens serve to provide information about an upco ming or completed action These screens are faded out auto matically after about 3 seconds No operator actions are possi ble during display of this screen 8 End menu IF the desired setups are executed the menu points can be used to scroll to the menu point E of the first level 9 Confirming with ENTER changes the device back into operational readiness after the last operator action at every position with the N The menu is always automatically ended 60 seconds exception of when within SET UP menu P NOTE On safety grounds the garage door drive will not accept any commands while the menu is opened IF the menu is opened during the hold open time then the ge door drive will only close the door after ending the menu on the basis of a manual start command Only the level and the menu points are presented in the pro gramming manual which are required for execution of the desi r
20. 15 42 45cm jo 75 cm 8 3 AUTOMATIC CLOSING menu 3 Definition Operating mode with an automatic closing function according to an adjustable hold open time The function is func tionally independent of the function ventilation for automatic closing 1 Automatic closing may only be used in combination A with additional safety equipment photocell contract safety edge Activate the function in that menu b 3 is set to 1 active After activation automatic closing is additionally available to the menu point hold open time time up to bis automatic clo sing The hold open time can be setup there see 7 2 8 PROGRAMME DRIVE PARAMETERS MENU b 8 4 LIGHT BARRIER menu b 4 Definition Activation of the photocell evaluation Change the setup by activating the desired setting in menu b 4 O inactive no photocell Standard one way photocell 2 wires two wire photocell 8 5 SAFETY EDGE menu 6 5 Definition Activation of the safety edge evaluation Change the setup by activating the desired setting in menu b 5 O inactive no safety edge active Ohmic safety edge 8 2 RQ 8 6 FUNCTION CAUTION LIGHT menu b 6 Definition Selection of the externally attached caution light signalling lamp types see 4 7 1 8 7 SELECT CAUTION LIGHT menu b 7 Definition Selection of the caution light Function to an external Signalling device and or integral drive light s
21. 8 B WAY radio hand transmitters can be programmed dependent on the free storage space Hand transmitter remote control is available with the Home wave Control Box HWC For a description of the functions see the operating manual for the HWC WLAN uplink to the internet HWC web service software and a compatible peripheral device tablet laptop PC with an internet connection are necessary Operation and status enquiries over a smart phone are availab le with HWC and a BERNAL app an 105 or Android compatible smart phone with WLAN is necessary The HWC and a BER NAL app simply need to be programmed once like a radio hand transmitter in the drive Only for the version of the device without a display acceptance testing of the drive hood is essential for performing the pro gramming deletion of radio hand transmitters Figure 35 the covers on the 230 V AC area of the control board see Figure 40 should never be removed 61 PROGRAMME A RADIO HAND TRANSMIT TER Every B WAY radio hand transmitter must be programmed once in the receiver memory of the garage door drive This mes sage remains if there is a power cut power failure changeover to battery power B WAY should be held at arms length from the drive receiver during the programming process V Activate programming and enter menu 1 Enter Programme a hand transmitter The drive signals Wait for the hand transmit ter see programming manual Select th
22. BE Firmly screw on the lintel fastening bracket using suitable screws and washers Lift the rail and attach to the lintel fastening using M8x75 bolts as well as washers and self locking nuts If the rail is not fastened directly to the ceiling N but rather by using suspension brachets proceed with 3 2 3 Figure 22 Swivel the rail on the ceiling a and support Check for horizontal alignment using the spirit level check for central alignment of the previously Picture 14 traced middle of the door leaf b Trace the bore holes through the head mount observing ensu ring that there is a suitable substrate c Lay the rail on the floor and cover it to protect it against drilling dust Drill the holes a and clean the area if necessary use a devi ating drill diameter according to a suitable fastening material Insert dowel swivel the rail on the ceiling and tightly fasten down using suitable fastening material b 3 2 3 INSTALLATION OF THE RAIL USING SUS PENSION BRACKETS As an alternative to assembly on the ceiling 3 2 2 Note figures 14 21 correspondingly Place the middle suspension on the rail a and align b Swivel rail on the ceiling a align using the spirit level b and support Place the suspension bracket on the middle suspension and align flush with the ceiling Check the ceiling at the intended fastening position for a sui table substratel Trace the lower edge of
23. BERNAL TORANTRIEBE USER MANUAL G 501 WWW bEISNAL DE 1 1 1 2 1 3 1 4 2 l 2 2 221 2 2 2 2 3 23 23 2 2 3 3 2 3 4 235 2 3 6 2 3 2 4 2 4 2 4 2 3 31 3 1 3 2 3 2 3 2 2 3 2 3 3 2 4 3 2 5 3 2 6 3 2 7 3 2 8 3 2 9 BERNAL TORANTRIEBE CONTENTS GENERAL INFORMATION ASSEMBLY AND OPERATING MANUAL STORAGE AND TRANSPORT SCOPE OF DELIVERY APPROPRIATE USE SAFETY INSTRUCTIONS SYMBOLS GENERAL SAFETY INSTRUCTIONS DOOR MOVEMENT EMERGENCY RELEASE SAFETY INSTRUCTIONS FOR ASSEMBLY COMMISSIONING SERVICING REPAIR WORK DISASSEMBLY QUALIFIED SPECIALIST PERSONNEL ACCIDENT PREVENTION FASTENING THE DRIVE AND FASTENING MATERIAL ELECTRICAL INSTALLATION COMMISSIONING ALTERING THE MACHINE SERVICING AND REPAIR WORK SAFETY INSTRUCTIONS FOR OPERATION OPERATION CHECKING ASSEMBLY PREREQUISITES FOR INSTALLATION CONDITION OF THE DOOR AND THE INSTALLATION SITUATION ASSEMBLY ASSEMBLY OF THE RAIL INSTALLATION OF THE RAIL ON THE CEILING INSTALLATION OF THE RAIL USING SUSPENSION BRACKETS ASSEMBLY OF THE HEAD OF THE MOTOR MOUNTING THE DOOR FASTENING BRACKET ASSEMBLY OF THE OUTER RELEASE SYSTEM ASSEMBLY OF THE INNER EMERGENCY RELEASE SYSTEM MANUAL FUNCTION TEST ATTACHING THE WARNING SIGNS 3 210 ADAPTING THE RAIL LENGTH 4 4 2 4 3 4 4 4 5 4 6 4 7 4 71 4 7 2 4 8 5 1 5 2 5 3 5 4 5 5 PROFESSIONAL EXTENSIONS ELECTRICAL CONNECTION
24. S OVERVIEW OF THE CONTROL BOARD START BUTTONS STOP WICKET DOOR CONTACT CONTACT SAFETY EDGE TWO WIRES PHOTOCELL ONE WAY PHOTOCELL RELAY PK CAUTION LIGHT RELAY FUNCTION ADDITIONAL LIGHT ANTENNA INITIALISATION SET UP MENU P PREREOUISITES SET UP OF THE GARAGE DOOR DRIVE DOOR TYPE PROGRAMME RUNWAYS PROGRAMME FORCE CURVE 6 RADIO 61 PROGRAMME RADIO HAND TRANSMITTER MENU C1 62 DELETE A RADIO HAND TRANSMITTER MENU 2 3 63 REPLACE BATTERY IN RADIO HAND TRANSMITTER PROFESSIONAL EXTENSIONS 7 PROGRAMME DRIVE FUNCTIONS 7 SETUP FORCE MENU F 72 TIME TILL AUTOMATIC CLOSING MENU A 73 WARNING TIME CAUTION LIGHT MENU U 74 LIGHT MENU L 75 SPECIAL FUNCTIONS MENU 5 751 FUNCTION VENTILATION MENU 51 53 7 5 2 FUNCTION RELAY PK MENU S4 753 FUNCTION LIGHT MENU 55 8 PROGRAMME DRIVE PARAMETERS MENU b 8 1 REVERSION MENU b 1 82 SOFT START STOP MENU b 2 83 AUTOMATIC CLOSING MENU 3 8 4 LIGHT BARRIER MENU b 4 85 SAFETY EDGE MENU b 5 8 6 FUNCTION CAUTION LIGHT MENU b 6 8 7 SELECT CAUTION LIGHT MENU b 7 8 8 RESET PARAMETERS FACTORY SETTINGS MENU 8 9 91 OPERATOR BRIEFING 9 2 OPERATION 93 OPERATING MODE 94 OPERATING CONDITIONS lO OPERATING FAULTS 10 1 ERROR MESSAGES 10 2 TROUBLESHOOTING I MAINTENANCE 11 WEAR PARTS 11 2 OVERVIEW OF PARTS 12 INSPECTION 121 INSPECTION SPECIFICATIONS 122 CHECK OBSTACLE DETECTION FORCE CUT OFF 13 ACCE
25. SSORIES l4 DISASSEMBLY AND DISPOSAL 14 1 DISASSEMBLY 14 2 DISPOSAL 15 WARRANTY CONDITIONS 16 TECHNICAL DATA 17 DECLARATION OF INCORPORATION 18 MANUFACTURER 19 SERVICE ANNEX Al DOCUMENTATION WITH INSPECTION BOOK A2 PROGRAMMING MANUAL BERNAL TORANTRIEBE I GENERAL INFORMATION Dear customer May we thank you for deciding to invest into a modern quality product from our company Please first read through all of this manual before beginning with the assembly and installation of the device 1 1 ASSEMBLY AND OPERATING MANUAL This original assembly and operating manual the inspection book as well as manual for the garage door and possibly further installed elements are all integral components of the full pro duct documentation for the machine The product documenta tion should be kept in safe keeping in such a way that all per sons commissioned with operation servicing or repair can gain access to it ATTENTION IMPORTANT SAFETY INSTRUCTIONS IT IS IM PORTANT FOR THE SAFETY OF PERSONS TO COMPLY WITH THESE INSTRUCTIONS THESE INSTRUCTIONS SHOULD BE IKEPT IN SAFE KEEPING ATTENTION IMPORTANT INSTRUCTIONS FOR SAFE ASSEM BLY OBSERVE ALL INSTRUCTIONS WRONG ASSEMBLY CAN LEAD TO SERIOUS INJURIES 1 2 STORAGE AND TRANSPORT The garage door drive should be stored transported in the temperature range 20 C to 40 C and non condensing a rela tive air humidity RF of 20 80 The maximum stach h
26. STRUCTIONS FOR OPERATION 2 4 OPERATION General danger of injury to persons and damage to equipment Operation of the door may only be performed by authorised users who have been instructed in operating the machine This device is not designed for use by persons including child ren with limited physical sensory or mental capabilities or who have little or no experience and or little or no Rnowledge un less they are being supervised by a person authorised to ensu re their safety or have received from him instructions on how to use the device Firmly installed control elements buttons etc must be placed away from the reach of children at a minimum height of 15O cm above the ground Do not let children play with the machine Control elements for remote control radio hand transmitter and peripheral devices with the HWC web service and or the HWC operating app must be hept out of the reach of children Do not keep radio hand transmitters in ones trousers or hand bag to avoid unintentional actuation of buttons The machine may only be actuated as long as the whole area of movement of the door is visible from the operating location IF this cannot be arranged for example for automatic closing then the machine must be fitted out with additional safety equipment Remote control of the machine with a view of the door via a radio hand transmitter and or peripheral devices with the HWC web service and or the HWC operating app is not
27. The light can be set up in 7 stages from O sec to 300 sec This does not regulate the general function of the drive light on off flashing Remote control of the integral drive light see 7 5 3 For use of the integral drive light with caution lights function see 4 7 1 7 5 SPECIAL FUNCTIONS menu 5 751 FUNCTION VENTILATION menu 5 1 to S 3 Definition Additional freely selectable door position which can be used either as a ventilation function for the garage or as a partial opening position for example for pedestrians on a side sectional door Any desired door position can be selected for the ventilation position between the end positions Door Closed and Door Open dio hand transmitter a channel for the radio hand transmitter s must be programmed for Ventilation see 6 1 For the version of the device with a display the function can alternatively be actuated over the display The function can only be employed when using should be initially moved with the drive into the desired door position no drive movement is possible in menu S bis S 3 In operating mode Automatic closing it is not possible to programme the function the door cannot be stopped in the intermediate position temporarily deactivate the operating mode Automatic closing for activation of the ventilation function For activation of the ventilation function the door I PROFESSIONAL EXTENSIONS 1 Function v
28. achine is not permitted until it has been established that it complies with the provisions of this directive Pfullingen 01 03 2013 Willi Prettl Managing Director 18 MANUFACTURER Manufacturer of the garage door drive is the manufacturer na med at chapter 17 19 SERVICE Please contact your local professional dealer or fitter for service maintenance repair or check of the plant Request due to the garage door drive will be answered by the manufacturer of the garage door drive named at chapter 17 For complete contact data please note the type sign of the garage door drive 38 Al DOCUMENTATION WITH INSPECTION BOOK Submission for the product documentation including the ins pection book inspection report handover declaration and ma nufacturer declaration This submission can be use by the spe cialist assembly company while alternatively own submissions can also be used Status of this annex November 2012 Important information for the manufacturer as sembly fitter for the machine The inspection booh is a component part of the product docu mentation and should be handed over to the owner operating company at the time of commissioning in a carefully and fully filled out condition A component part of the full product docu mentation apart from the inspection book is the EC Conformi ty Declaration the operating manual as well as the cheching servicing instructions for the machine or its individual compo nent
29. after activation the integral drive light remains until a new operating command Light or Start active in the latter case the light ends after the set lighting period Alter the setup in menu 5 5 to active if the Function is desired For actuation over the radio hand transmitter it is necessary to programme one channel of the radio hand transmitter in additi on to Light see 6 1 27 28 BERNAL TORANTRIEBE I PROFESSIONAL EXTENSIONS 2 3 1 2 3 2 2 3 5 2 3 6 2 3 7 8 1 REVERSION menu b 1 Definition If the door meets an obstacle when moving in the di rection Close force cut off occurs and release from the obstac le through moving back reversing in the direction Opening Reversing can be selected in the operating mode see 9 3 im pulse operation to in the end position door fully opened or door reversed by about 10 cm Note In automatic clo sing mode reversing always occurs into the end position Door Open Change the setup by activating the desired setting in menu b 1 O end position 10 8 2 SOFT START STOP menu 6 2 Definition Length of the phase with which the door drive starts Up or stops at a slow stops soft start soft stop The soft running phases with 45 or 75 cm can be necessary on doors with difficult movement cycles or force cycles Change the setup by activating the desired setting in menu b 2 Q 7 G
30. al technical documentation was created according to Annex VII 8 The person responsible EC documentation Is please put a cross against the relevant items the Managing Director of the company named as the manufacturer other Name Street name house number Postal code place Commissioning of the machine is not permitted until it has been established that it complies with the provisions of this machine directive Place date Name function 43 Al 4 CHECKING REPORT copy Test certificate for power driven doors according to EN 12635 Model designation Serial No The above mentioned machine was submitted today to full checking according to the servicing and checking instructions The checking procedures discovered no deficits the following deficits add additional documentation separately as an annex if necessary and required measures to be taken the listed deficits were removed the listed deficits could not be removed today other OOL Date Name Company des Signature The above mentioned machine was repaired today and also subjected to repeated checking The checking procedures disco vered the listed deficits were removed Date Name Company des Signature 44 AL5 HANDOVER REPORT 1 Copy for the Assembly company Owner operating company The machine specified under 1 13 if necessary after a repeat inspection Model designation Ser
31. all 4 channels buttons of a radio hand transmitter can be pro grammed respectively for any desired function on 4 different garage door drives or two channels buttons of a radio hand transmitter can be pro grammed one after the other for respectively two functions on 2 different garage door drives 15 not possible for example to programme Channel 1 Button 1 of the same radio hand transmitter one after the other for a number of different garage door drives If a channel which has already been programmed in a garage door drive is program med into another garage door drive then the previously pro grammed garage door drive will be removed from the memory 6 2 DELETE RADIO HAND TRANSMITTER Deleting one hand transmitter Activate programming and enter menu C 2 Delete a hand transmitter The drive signals Wait for the hand transmitter Actuate one of the programmed channels buttons of the desi red radio hand transmitter until the garage door drive confirms the deletion Further channels on the same B WAY which may also have been programmed e g a second channel for a ventilation func tion are deleted automatically Repeat the procedure for further B WAY radio hand transmit ters or further channels on the same device Finally leave the programming screen occurs within about 60 sec if there is no action the garage door drive moves bach automatically into operational readiness Deleting all radio
32. ard continuously shows a 3 digit error code F 0 5 sec DIGIT A 0 5 sec DIGIT B 05 sec An example F 1 2 means F12 Error 12 The fault indication appears with error code and a plain text dis play in the display Error reporting over the HWC app or HWC web service See ma RESET Auto Reset Auto Reset Auto Reset Auto Reset Confirm with Enter Confirm with Enter Confirm with Enter Manual reset Manual reset Manual reset Manual reset Manual reset Auto Reset Auto Reset Auto Reset Auto Reset Auto Reset Auto Reset Auto Reset Auto Reset Auto Reset Auto Reset Pull out the power plug wait for about 10 seconds plug in the power plug again and wait for the device to do a self diagnosis 3l 32 10 2 Troubleshooting THE PROBLEM No function No function via the START terminals No function over radio Radio range low The doorruns a short time and then it stops without new installation The doorruns a short time and then it stops during first initiation The door runs for a short time and then it stops reverses Door does not stop reverses immediately after running into an obstacle No function despite motor noises Toothed belt sgeaks chain chatters Water in the drive Door grinding on the drive rail The door closes by itself The door opens closes stops by itself Door starts off slowly The door only runs in
33. ation of any applica tions Actuation takes place over the radio hand transmitter In itially programme a free channel of a radio hand transmitter for the function Relay see 61 Then activate PK in that the signal type of is selected in the menu 5 4 Relay function For a continuous signal activate menu 5 4 to Continuous the relay is activated for the operating command and remains active until a renewed operating command use for example additional light For an impulse signal activate menu S 4 to 2 Impulse the relay produces an impulse of about O 5 sec for every operating command use for example automatic staircase light yard gate drive 4 8 ANTENNA Installation of an outer antenna can be necessary according to local conditions to increase the range The antenna must be designed for 868 35 MHz and be fitted with a screened cable An optimal result is only achievable when the outside antenna is installed outside the garage at the highest possible location as well as in view of the operating location bidirectional radio receiver BERNAL B WAY 868 35 MHz Radio receivers connected over the HW ERW adapter cannot be actuated N The antenna connection is only effective for the integral Remove the wire antenna installed at the works Connect the inner conductor of the outer antenna to terminal JA and the screen for the outer antenna to terminal The inner conductor and screen m
34. connected to the terminals L and L The terminal designation for Figure 46 47 is that of a BERNAL photocell with the type designation B 210 090 For use of one way photocells with a contact safety edge see Figure 47 When using the 2 pairs of photocells Mount the pairs respec tively optically worhing in opposite directions connect up swit ching outputs for the receiver RX in series Triggering of a photocell during opening is ignored Triggering of a photocell during closing leads to Stop and Reversing VU OWAC 24V AC VU OVIAC VU 24V AC A b 4 ONE WAY PHOTOCELL 8 2 Recognition of a one way photocell must be activated in N the menu b 4 to 11 Recognition of the contact safety edge must be activa ted in the menu b 5 to 1 see figure 46 Triggering of the photocell safety edge during opening is ig nored Triggering of the photocell safety edge during closing leads to Stop and Reversing RX BERNAL B 210 090 VU OVIAC VU 24VIAC 14 0 250 VU OVIAC VU 24VIAC 2l 22 BERNAL TORANTRIEBE I PROFESSIONAL EXTENSIONS 4 7 RELAY PK is a potential free relay output for various functions can be externally loaded with max 250 V AC A 1 AT fuse is necessary The parallel simultaneous use of the various functions is not possible The warning light function 4 7 1 takes pr
35. du ve chapter please look in the respective headline at the A ring set up top right The automatic obstacle detection force cut off is NOT EFFECTIVE during set up A Programming may only be performed by a professional fitter TABLE OF CONTENTS PROGRAMME POINT MENU PAGE BUTTONS AND OPERATION OF THE MENU 02 OVERVIEW OF THE STRUCTURE OF THE MAIN MENU LEVEL 1 O4 SETUP SETTING FORCE DISTANCE TRAVEL PATH AND FORCE CURVE P O5 SETUP TRANSMITTERS PROGRAMMING A HAND TRANSMITTER C I 06 SETUP TRANSMITTERS DELETE A HAND TRANSMITTER 2 07 SETUP TRANSMITTERS DELETE ALL HAND TRANSMITTERS C 2 08 SETUP FORCE F 09 TIME TILL AUTOMATIC CLOSING A 10 WARNING TIME CAUTION LIGHT U 10 LIGHT AFTERGLOW TIME L 10 SPECIAL FUNCTIONS FUNCTION VENTILATION S I lI SPECIAL FUNCTIONS AUTO CLOSING VENTILATION S 3 11 SPECIAL FUNCTIONS FUNCTION RELAY S 4 12 SPECIAL FUNCTIONS FUNCTION LIGHT 5 5 12 DRIVE PARAMETERS REVERSION 13 DRIVE PARAMETERS SOFT START STOP b 2 13 DRIVE PARAMETERS AUTOMATIC CLOSING b 3 13 DRIVE PARAMETERS LIGHT BARRIER b 4 13 DRIVE PARAMETERS SAFETY EDGE b 5 13 DRIVE PARAMETERS FUNCTION CAUTION LIGHT b 6 13 DRIVE PARAMETERS SELECT CAUTION LIGHT b 7 13 DRIVE PARAMETERS RESET PARAMETERS FACTORY SETTINGS b 8 13 Ol 02 BERNAL TORANTRIEBE BUTTONS AND OPERATION OF THE MENU G 501 with a display is fitted with 3 buttons which are located on the right next to the graphics display After pressing a but ton the display is
36. e cable FO4 Door path not programmed or FO5 Fault on the motor 206 HALL sensor defective FO7 Processor error FO8 ROM error FO9 RAM error EEPROM error FII Error in the parameterisation F12 Error on a peripheral device F13 Overcurrent in the end stage F14 Double error on the motor actuation F15 Transformer error F16 Overload on the drive F17 Undervoltage on the power supply network F18 Blocking the Start button F20 Communication error external extension F21 Communication error 868 radio F22 Communication error BT WLAN Auto Reset the cause is removed The error is cancelled automatically as soon as nual for the respective accessory CAUSE Power supply network voltage too high Connection L L triggered EMERGENCY connection triggered Photocell safety edge cable or connections defective loose Setup failed or not executed yet Motor or connection cable for the motor possibly also a sensor cable defective loose The sensor or sensor cable is defective loose gearbox worn defective Controlling error Controlling error Controlling error Controlling error Controlling error Connection error or controlling error Controlling error or defect Controlling error or defect Transformer cannot be switched in defective Obstacle detection force cut off triggered Power supply network voltage too low Continuous signal to the Start connection Data transm
37. e desired hand trans mitter function Perform the programming of the radio hand transmit ter on the basis of the programming manual after you have informed yourself about the general processing sequence from the following information Door run remote control of the door 2 Ventilation remote control of the ventilation function 3 Light remote control of the integral drive light 4 Relay remote control of the relay PIK Press the desired button channel 1 2 3 or 4 on the radio hand transmitter until the drive see programming manual or the radio hand transmitter simultaneous lighting up of the green LED and the red LED confirms successful programming Repeat the procedure for additional B WAY radio hand trans mitters or further channels on the same radio hand transmit ter for further functions Finally leave the programming screen occurs within about 60 sec if there is no action the drive receiver moves bach automatically into operational readiness NOTE every channel of a radio hand transmitter can only be programmed for one garage door drive Examples all 4 channels buttons of a radio hand transmitter can be programmed one after the other for 4 different functions of the same garage door drive or all 4 channels buttons of a radio hand transmitter can be programmed one after the other for the same function on the same garage door drive a safety function Operation using any button
38. e door by garage door drive into the desired ventilation position before beginning programming 5 1 Activate deactivate the function ventilation Auto closing ventilation may only be used in combinati additional Display for 5 1 active BERNAL TORANTRIEBE SPECIAL FUNCTIONS FUNCTION RELAY MENU S A SEE 7 5 2 t O 1 o maa DRIVE PARAMETERS MENU b SEE 8 ff u mMm 1e 12 b 2 Soft start stop length J OD me s b 3 Automatic closing mo p a 10 te O e BERNAL TORANTRIEBE For warranty claims spare parts requests or questions proper installation of your product please contact our BERNAL partners www bernal de service servicestellenverzeichnis Version 1 2014 Urheberrechtlich geschutzt 2014 BERNAL Torantriebe GmbH alle Rechte vorbehalten Jede vom Urheberrechtsgesetz nicht zugelassene Verwertung insbesondere Vervielfaltigung Ubersetzung Verarbeitung bzw Weitergabe von Inhalten in Datenbanken oder anderen elektronischen Medien und Systemen ist verboten Protected by copyright 2014 BERNAL Torantriebe GmbH all rights reserved For every utilization especially duplication translation converting or transfer of content in databases or every other electronic media or systems not approved by
39. ea of the door must be fenced off or secured against unauthorised entry on foot or driving in and or secured before any checking takes place The machine should be checked at regular intervals by a skilled person according to the inspection book for a secure condition and function Function testing of the integral and attached safety eguipment must be undertaken monthly by the owner operator Simple optical inspection of all moving components and faste nings can be performed by the owner operator annually The inspection book is a component part of the product docu mentation and should be kept in safe keeping and secured so that the person commissioned to perform checking servicing or repair work can have access to it IF any deficits are discovered during checking the machine should be taken out of action totally shut down and repaired by a professional fitter before re commissioning The machine may only be commissioned again when a secure condition was established BERNAL TORANTRIEBE 22 222 231 232 233 235 236 3 1 PREREQUISITES FOR INSTALLATION A protective grounded contact sochet is essential for the power supply to the device This must installed in an area 50 cm the end of the drive by a trained electrician Prepare any tool s as well any aids for supporting the drive in the garage for use Figure 5 Check the scope of delivery Figure 1 2 and its condition Drives which have recognisable
40. ecedence and prevents the use of PK as a free relay AN n N max 250V max b 4 4 7 CAUTION LIGHT First select the signal type in menu b 6 Caution light function see 8 6 for a rotating mirror beacon or caution light with its own clocking menu b 6 to 2 Continuous signal should be activated for a signalling lamp without its own clocking menu b 6 to 1 Flashing should be activated for a signalling lamp without its own cloching and integral drive light menu b 6 to 1 Flashing should be activated if only the integral drive light flashes b 6 to 1 Flashing should be activated in this case continues to be used as a free relay 4 7 2 Subsequently activate the function in the menu b 7 Caution light selection if only the external caution light should actuated on PK menu b 7 to 2 Relay is to activated if the integral drive light should also flash to the menu b 7 to 3 both relay and integral drive light should be activa ted if only the integral drive light should flash menu b 7 to 17 Light is to activated Menu U is released in parallel This is where various pre war ning times for the caution lights are selected see 7 3 4 7 2 RELAY FUNCTION ADDITIONAL LIGHT The variant is not possible if PK is already used as an external as a caution light connection can be used as a free relay for actu
41. ed setup All levels of a menu or sub menu are continuous that means when one continues to scroll downwards at the lowest position of a menu then the selection begins again at the uppermost position of the level 03 O4 BERNAL TORANTRIEBE OVERVIEW OF THE STRUCTURE OF THE MAIN MENU LEVEL 1 n 1 SISleisisleisisiers SETUP Programme travel paths programme force curve Far information see Operating manual Chapter 5 17 Continue to page 4 RADIO PROGRAMMING Programme delete radio hand transmitter For information see Operating manual Chapter 6 Reaction behaviour for force cut off Far information see Operating manual Chapter 7 1 Continue to page 8 Setup the time limit till closing for the operating mode Continue to page 8 PREWARNING TIME Available if b 6 active Delay lime required for the caution light to setup For information see Operating manual Chapter 7 3 Continue to page 8 LIGHT Setup the afterglow time of the integral light system For information see Operating manual Chapter 7 4 inue to page 8 SPECIAL FUNCTIONS Ventilation function relay function remote control of the light For information see Operating manual Chapter 7 5 Continue to page 9 10 DRIVE PARAMETERS Reversion Soft run Automatic closing Photo cells Safety edge Caution light Factory settings Continue to page 11 LANGUAGE SELECTION Back into Stand by with ENTER As an alternative with DOWN t
42. ee 4 7 1 8 8 RESET PARAMETERS FACTORY SETTINGS menu b 8 Definition Reset all individual settings to the basic setting made at the factory parameters with a black background in the programming manual individual settings which are execu ted after set up are deleted irrevocably travel paths error messages as well as all individual connection and function settings Storage of radio hand transmitters remains intact VW Reset deletes all saved data in the areas force curve Trigger by activating menu b 8 to I 9 221 222 236 241 242 9 1 OPERATOR BRIEFING Ensure that the owner operator is trained in safe operation of the machine as part of the hand over process We recommend explanation and demonstration directly on the object safe operation of the plant while observing all of the safety instructions the location and function of all control elements and safety equipment as well as their effect during the various operating conditions safe use of the manual emergency release system the arrangement and significance of the warning signs the operating conditions 9 2 OPERATION Operation of the door movement function of the garage door drive can take place over the radio hand transmitter the drive display only for the version of the device with a display as well as over optional control elements connected to the START con nection accessory The drive reacts to operating co
43. eight in each case is 6 motor heads or rails or complete devices pached in a Rit carton Stached de vices must be secured against falling over 1 3 SCOPE OF DELIVERY The scope of delivery can deviate dependent on the device or rail version from figures 1 and 2 1 4 APPROPRIATE USE The garage door drive is designed for automation of non com mercial counterweighted garage doors within an integral anti derail device within its technical limits of use The garage door drive can be used on the following door types Figure 3 Swinging doors a e overhead tilting doors and canopy doors b the accessory the curved door arm essential sectional doors c Side sectional doors d e 2 leaf doors Double leaf doors e the accessory the double leaf door fittings essential 2 SAFETY INSTRUCTIONS ATTENTION IMPORTANT SAFETY INSTRUCTIONS IT IS IM PORTANT FOR THE SAFETY OF PERSONS TO COMPLY WITH THESE INSTRUCTIONS THESE INSTRUCTIONS SHOULD BE IKEPT IN SAFE KEEPING 2 1 SYMBOLS Various symbols are used in the assembly and operating ma nuals to refer to dangers Important safety instruction Non observance of these instructions can lead to personal injuries through to im mediate fatal injuries Non observance of these instruc tions can lead to severe damage to equipment through to total destruction of the product Important safety instruction Contact with the power N network voltage can lead to pers
44. elements Fix the warning label which refers to operation of the emergen cy release system on a clearly visible place or near the emer gency unlocking system Permanently fix the warning label which refers to the fact that children should not be in the area of the opened door on clear ly visible place near the swivel area of the door 3 210 ADAPTING THE RAIL LENGTH In tight installation situations the rail can be shortened in order to reduce the total length of the drive Here the maximum path traversed by the device the maximum door height also redu ces by the amount reduced Only perform the shortening on the front end of the rails nthe case of split rails the side with the dead stop for the cap rails see Figure 6 must not be shortened The shortened part of the rail must have a minimum length of 500 mm Perform the shortening using a suitable metal saw blade on an electrical saw with guide Shorten the lengths of the chain and the toothed belt appropriately the amount of the reduction in length of the rail x2 for example shortening of the rail by 250 mm requires a shortening of the chain or toothed belt by 5OO mm Unpack the rail and pull the chain toothed belt with deflection head mount and carriage out of the rail Shorten rail and deburr Unlock the carriage see Figure 12 and pull the carriage from the drive dog Toothed belt version Remove the securing screw 1 using a Phillips screwd
45. entilation menu 5 1 Initially move with the drive into the desired door position Activate the function in that menu 5 1 to active is switched Then save the door position 2 Position ventilation menu S 2 Adopt the current door position as the ventilation position in that menu 5 2 to 1 adapt is switched Then set up or switch off the automatic closing 3 Auto close ventilation menu S 3 Definition The time period which expires between stop in the ventilation position and the automatic closing of the door The hold open time can be set up in 9 stages 30 min to Continuous The function is functionally independent of the function automatic closing 8 3 Auto close ventilation may only be used in combination A with additional safety equipment photocell contract safety edge Activate Auto close ventilation by changing the setting of S 3 from continuous closing is only possible based on a manually triggered radio hand transmitter com mand to the desired value 7 5 2 FUNCTION RELAY PIC menu 5 4 Definition Allows selection of the relay contact to inactive continuous signal or impulse signal For an explanation see 4 7 2 Change the setup by activating the desired setting in menu 5 4 7 5 3 FUNCTION LIGHT menu S 5 Definition Allows operation of the integral drive light inde of the drive function over the display or radio hand transmitter
46. es force values specified in Standard EN 12453 must be demonstrated with appropriate measuring eguipment by the competent person who has carried out the adjustment To the extent that this is allowed by law BERNAL assumes no liability for damage caused by improper changes to the closing force settings The PIN reguired for changing the closing force settings is 5283 F Setup the force of the drive PIN input is required lt q Selection of the digit from 0 9 lt Selection of the next digit of the PIN lt ENTER Explanation of the PIN entry After selecting the menu item Force with ENTER PIN entry is carried out For this select the first digit of the PIN with by entering change to the next PIN digit Repeat the procedu re of selecting the digits with and changing to the next digit of the PIN by entering for the second and third digit of the PIN After selecting the fourth digit of the PIN with press on ENTER If the PIN entry was correct you can adjust the force of the drive Next Page 10 09 BERNAL TORANTRIEBE Continued from page 09 TIME TILL AUTOMATIC CLOSING MENU A SEE 7 2 A Select delay for automatic closing from point in time Door opened x seconds prewarning before opening SEE 7 3 L Select aftengiow time of the integral drive light SPECIAL FUNCTIONS FUNCTION VENTILATION MENU S 1 TO 5 3 SEE 7 5 1 Move th
47. highest door running point TLP The drive must be installed behind the TLP if this minimum clearance is not achieved The accessory push rod extension is necessary the installation depth of the garage door drive ext ends according to the push rod extension AII mechanical locks on the door should be removed completely The upper edge of the door must have an adeguately firm upper edge for fastening the door fittings recommendation min of mm An additional load carrying device should be used for sectional door fittings BY 4720 on an unstable door The garage door drive is aligned horizontally as well as above the middle of the door as well as in the alignment of the door leaf Check that the lintel and ceiling have an adequate stability in the area planned for fastening of the garage door drive and have a suitable substrate prepare suitable fastening material for use if necessary 3 2 ASSEMBLY 3 21 ASSEMBLY OF THE RAIL The rail can be delivered in various level of preconfigurations according to the device version individual steps can develop if necessary UnpacR rail observe pachaging notes and lay to one side Insert parts of the rail on both sides up to the pressed in end stop 1 into the cap rail s Lead toothed belt or chain into the rail observe that the drive dog 2 lies on the right side of the rail and pull on the deflec tion roller unit 1 in the direction of the end of the rail The drive dog i
48. ial No complies with the pertinent European and national guidelines and standards I GB Handover of the machine has please put a cross against the relevant items taken place after finishing all installation and setting up work taken place in an operable condition after full final checking and function testing taken place in a deficient condition The owner operating company please put a cross against the relevant items was instructed in safe operation of the machine was advised about checks which he should make regularly was advised about his duty to have the machine checked regularly by a competent person The product documentation was handed over including please put a cross against the relevant items Assembly manual s Operating manual s Servicing cheching instruction s Inspection book Manufacturer declaration Declaration s of incorporation First checking report other Place date eo For the fitter assembly company For the owner operating company Name L Name 01 Signature EOE EE EE EE EE ES Signature 45 46 AL5 HANDOVER REPORT 2 Copy for the Assembly company Owner operating company The machine specified under 1 13 if necessary after a repeat inspection Model designation Serial No complies with the pertinent European and national guidelines and standards Handover of the machine has plea
49. illuminated and illumination ends about 60 seconds after the last action In operational readiness 1 the ga rage door drive can be operated over the display and buttons in that the respective command with a black background is con firmed using ENTER button C Buttons and button function Button A Selection UP scroll upwards in the displayed list Button B Selection DOWN scroll downwards in the displayed list Button C ENTEI Confirm selection or within the menu confirm the selection and go back into the previous level The respectively selected command has a black background and can be actuated using the ENTER button In some screens additional information is displayed upon pres sing on ENTER An example based on Open menu Open menu On safety grounds the menu can only be opened in that 5 tup is confirmed by pressing ENTER and holding it down for 3 seconds The information Hold 2 appears in the display Presentation in the programming manual Each of the following pages always begins in the normal con dition Operational readiness at the upper left The sequence of the steps tahes place based on what is shown on the screen Buttons which should be pressed to execute the setup have grey bachground 3 Actions which occur due to pressing of a button are displayed with an arrow Actions which occur automatically are displayed with the dos hed arrow Optional actions for example scroll
50. in parallel Triggering of a Stop command leads to Stop or prevents start of the garage door drive 2x0 259 Triggering of a safety edge during opening is ignored Triggering of a safety edge during closing leads to Stop and Reversing 20 BERNAL TORANTRIEBE I PROFESSIONAL EXTENSIONS 4 5 TWO WIRES PHOTOCELL Recognition of the two wires 5 must be activa ted in the menu b 4 to 2 One pair of two wire photocells with a reaction time lt 500 ms can be connected to the terminals L and L The terminal designation represents the BERNAL photocell The connections for the receiver RX and transmitter TX are replaceable For use of two wire photocells and contact safety edges see Figure 45 Triggering of a photocell during opening is ignored Triggering of a photocell during closing leads to Stop and Reversing Recognition of the two wires photocell must be activa ted in the menu b 4 to 2 Recognition of the contact safety edge must be activa ted in the menu b 5 to 1 V see Figure A44 Triggering of the photocell safety edge during opening is ig nored Triggering of the photocell safety edge during closing leads to Stop and Reversing I PROFESSIONAL EXTENSIONS 4 6 ONE WAY PHOTOCELL Recognition of the one way photocells must be activa ted in the menu b 4 to 1 One or two pairs of one way photocells with a reaction time lt 500 ms can be
51. ission error on the HW ERW connection Data transmission error in the area of the bidirectional radio 868 MHz Data transmission error in the area of the BT WLAN Manual reset RECOMMENDATION Create stable voltage conditions Release actuated safety element If necessary check safety elements connections and cable for defects Check safety elements connections and cable for defects Perform or repeat set up Check the connection cable for the motor replace motor if necessary Check the sensor cable plug replace motor if necessary Reset replace the control unit if necessary Reset replace the control unit if necessary Reset replace the control unit if necessary Reset replace the control unit if necessary Reset replace the control unit if necessary Check all connections systematically replace the control unit if necessary Reset replace the control unit if necessary Reset replace the control unit if necessary Check the primary secondary voltage replace the transformer if necessary Check the door running manually have the door repaired by a professional fitter if necessary Create stable voltage conditions Check the Start connection incl cabling and attached elements Repeat the action check the connection and hardware replace if necessary Repeat the action possibly less distance away Repeat the action possibly less distance away Check set up of the the components HWC smart phone trol bo
52. ive worn Chain wheel Crowm gear defective worn Chain toothed belt defective torn Toothed belt chain not tensioned correctly Toothed belt greased oiled Deflection drive sprocket bearing worn Condensate in the garage Ceiling drilled through installation Drive installed too low Automatic closing is activated Uncontrolled unintentional operation Caution light prewarning times activated The Hall sensor cable is loose defective Hall sensor or cable loose defective Gearbox defective Path traversed by the door too short min of about 3 sec 400 mm or too long max of about 45 sec 6500 mm Functions not activated in the menu OPTION Check power supply and preceding fuses Check fuses FI Check transformer replace Check control board replace Replace motor Deactivate check connections Check safety equipment Check repair Tighten terminals set jumper Check remove continuous signal Replace button or control element Check replace cable connections Programme transmitter Repeat the programming Check battery Replace transmitter Check receiver replace if necessary Check antenna Re programm the transmitter Use an external antenna Have the door serviced re programme travel paths and force Remove the obstacle Use a stronger drive Check correct Check correct Correct the installation situation Put the door into a condition which conforms to the standards Order a service by a qualified technician Remove
53. l as under voltage just for the ver sion of the device without a display Some areas of the control board carry 230 V AC the protective covers of the 230 area of the control board Figure 4O must not be removed Pull out the mains plug remove the hood plug in the mains plug again perform the activity pull out the mains plug attach the co vering hood again 3 Programming over a 7 segment display and buttons for the control unit only for the version of the device without a display 4 Programming programming and or deletion of radio hand transmitters only for the version of the device without a display no external voltage may be applied to the connecting terminals of the control board with the exception of the connection PK Connection of accessories is permissible for the quoted cable cross sections up to a maximum cable length of 20 metres The connecting cable for accessories must be routed separately from the cables carrying a current to avoid inductive signal transmissi on and the resulting faults 2 3 5 COMMISSIONING General danger of injury to persons and damage to equipment and being blocked out Two to three manually actuated opening and closing movements should be performed after assembly of the drive and before com missioning to check that the function of the door was not im paired On all garages without a separate second entrance the function of the emergency unlocking system should be checked afte
54. losed Do not move into the mecha nical limit of the door mechanism in full operation Resetting can be achieved using Run UP if necessary Store the desired position Door Up The set up assistant changes to Program ming run force 5 5 PROGRAMME FORCE CURVE Start the Programming movement for force by pressing once via Start programming run The door performs a full cycle Stop Close Stop The individual force values for the previously read in pathway points are measured out during this cycle and saved as an individual force curve The set up is ended automatically after successful program ming of the force The drive switches over into operational rea diness off see 12 2 Programme further hand transmitters or accessories if necessary and or programme the gara ge door drive correctly N After set up chech the the obstacle detection force cut ching product documentation the conformity declara To finalise the commissioning provide perform che i tion operator user briefing 23 24 BERNAL TORANTRIEBE 6 RADIO MENUC 2 2 1 2 3 5 The following information refers to the integral bidirectional ra dio system BERNAL B WAY General information For the bidirectional functions of the radio hand transmitter B status enguiry range checking battery condition indica tor please consult the manual for the radio hand transmitter Up to 12
55. mmands tart door moving as explained under 9 4 The integral drive light starts parallel to the drive start This can be switched as an alternative as a warning Function flashing if necessary with a prewarning function see 4 7 1 After Stop the integral light afterglows for a selectable time period see 7 4 The ventilation Function of the garage door drive is actuated over a channel to be separately programmed of the B WAY radio hand transmitter For the version of the device with a dis play actuation over the display is possible Special functions integral drive light relay are respec tively switched on or off over a separate channel to be separa programmed of the B WAY radio hand transmitter For functions controlled over the B WAY radio hand transmit ter the status messages Open closed or On Off can be queried at the radio hand transmitter see operating manual for the radio hand transmitter When the garage door drive is fitted with the Homewave Con trol Box HWC operation of the above mentioned functions is also possible using the BERNAL app additional safety equip ment required Apple 105 or Android compatible smart phone peripheral device necessary When the garage door drive is fitted with the Homewave Con trol Box HWC operation of the above mentioned functions is also possible using HWC web service software additional sa fety equipment required A WLAN U
56. nnae and can be pulled out to mahe a simple connection The cables for accessories should be guided according to Figu re 36 out if the drive housing BERNAL TORANTRIEBE OVERVIEW OF THE CONTROL BOARD FE RW aan partum TKTT p ne A WIN TK TAT ET a c BERNAL GM Art No mimi zer mo nM ri ES rt a am e ENTER SCHOLL DESIGNATION G402 G50l MODEL TYPE DESCRIPTION REMARKS START Yes Yes Terminal max 1 5 mm Start stop command see 42 NOT Yes Yes Terminal max 1 5 mm Start emergency stop command see 43 L Yes Yes Terminal max 1 5 mm Photocell VU 24 V AC see 4 5 4 6 L Yes Yes Terminal max 1 5 mm Photocell see 4 5 4 6 LS Yes Yes Terminal max 1 5 mm Photocell see 45 46 L Yes Yes Terminal max 1 5 mm Photocell VU O V AC see 4 5 4 6 Yes Yes Terminal max 1 5 mm Relay closer max 250 see 4 7 L Yes Yes Terminal max 1 0 mm Antenna cable screen see 4 8 A Yes Yes Terminal max 1 0 mm Antenna inner conductor see 4 8 BT WLAN Yes Yes 4P4C RJIO Connection for Homewave Control Box see manual for the resp accessory HW ERW Yes Yes 8P8C RJA5 Connection for hardware extension see manual for the resp accessory DISPLAY No Yes Display cable Connection for the display Equipment put on at the works HALL Yes Yes Molex 4 pin RM2 54 M
57. o the menu point or with UP to the menu point N SETUP SETTING FORCE DISTANCE TRAVEL PATH AND FORCE CURVE MENU sEEs lff For first initialisation or after reset to factory settings the setup assistant starts with the selection language The attached safety equipment is NOT EFFECTIVE during set up The automatic obstacle detection force cut off is NOT EFFECTIVE during set up OPTIONAL the door type must be setup first only for swing doors which open outwards O5 BERNAL TORANTRIEBE SETUP TRANSMITTERS PROGRAMMING A HAND TRANSMITTER MENU 1 SEE 6 1 Status Wart for hand transmitter ends affer 60 seconds if no radio SETUP TRANSMITTERS DELETE A HAND TRANSMITTER MENU 2 SEE 6 2 Status Wait for hand transmitter ends affer about 60 seconds if na radio signal is delete all transmitter 4l Failure X 07 BERNAL TORANTRIEBE SETUP TRANSMITTER DELETE ALL TRANSMITTERS MENU C 2 SEE 6 2 C i 1 10 E J 8 sten 8 cz t amp 10 4 08 SETUP FORCE MENU SEE 7 1 CAUTION Changing the closing force setting may lead to injuries to persons and or damage to property For this reason changing the closing force must only be carried out by a competent person approved by BERNAL If adjustment should be necessary compliance with the normative valu
58. och for the emergency release Rocker arm 139 70 B 139 71 B 440 401 B 440 403 D 210 090 B 126 05 BY 4100 N BY 123 length in cm E BY 123 length in cm D BY 4351 toothed belt BY 4353 toothed belt BY 4354 toothed belt various lengths on reguest BY 2230 BY 2231 BY 4720 BY 4700 B 146 66 B 146 02 BY 2221 14 DISASSEMBLY AND DISPOSAL 221 222 231 232 23 6 141 DISASSEMBLY Disassembly of the garage door drive should only be performed by a professional fitter while observing the accident prevention and safety regulations according to the assembly instructions but in reverse order of the worhsteps The power plug must be taken out and secured against plugging in again before begin ning the disassembly work 14 2 DISPOSAL Disposal of the drive should be undertaken according to the national and local disposal regulations The product or individu al components thereof must not be disposed of in the general house waste Directive 2006 66 Batteries are to be disposed of separa tely from the remaining components at local collection stations or by your dealer 35 36 BERNAL TORANTRIEBE 1 In addition to the legally required warranty provided by the dealer contained in the purchase contract we offer a warran ty on the following components of the garage door drive for a period of 5 years from the production date on the label and the control system for the respective
59. onal injuries through to immediate fatal injuries Important instruction for professional and correct instal lation programming and commissioning 2 2 GENERAL SAFETY INSTRUCTIONS 2 2 1 DOOR MOVEMENT I General danger of injury to persons and damage to equipment through impact being drawn in crushing The spring aggregates of the door are under very high tensions and can lead to the most severe injury to persons and damage to eguipment for improperly performed work All work on the mechanical components of the door may only be performed by professional fitters Wrong assembly commissioning or operation can trigger an unwanted drive and or door movement which can lead to the most severe injury to persons and damage to equipment There should be no persons in the area of movement of the door when the door is moving Reaching into moving parts of the drives guide rail chain too thed belt carriages push rod door fittings cable Bowden cables and the door guide rails spring aggregates rollers cables can lead to the most severe injury to persons 2 2 2 EMERGENCY RELEASE I Danger of injury to persons and damage to eguipment through impact being drawn in crushing being blocked out IF the mechanical components of the door are defective actu ation of emergency release of the drive can lead to immediate dropping down of the door A wrongly mounted cable and or Bowden cable on the emer gency release system can lead
60. oor as well as the lintel Recommendation for alignment of the drive in the longitudinal axis of the door Picture 20 Open the door fully and transfer the marhing from the upper edge of the door to the ceiling Open and close the door once fully to determine the highest door running point TLP a The TLP is the point of least distance between the upper edge of the door and the ceiling The lower edge of the door fastening bracket the rail is opti mally placed about 10 20 mm above the TLP b For a maximum angle a 30 the rail should not be fastened higher than 50 70 mm d above the closed door Observe horizontal alignment of the rail e A minimum clea rance between the upper edge of the door of 35 mm above the whole area of movement of the door is needed for orderly func tioning IF the above mentioned dimensions are not complied with ad ditional fastening material is necessary push rod extension and or a suspension bracket Trace the lintel fastening brachet in the middle of the door based on the previously determined height a Protect the drive and rail from drilling dust Drill the holes b and clean the area if necessary use a diffe rent drill diameter according to a suitable fastening material Put the dowel in place c Not shown as an alternative the lintel fastening can also be fastened to the ceiling turned upwards through 90 50 70mm E E e a BERNAL TORANTRIE
61. oor drive must be tahen out of ac tion totally shut down and repaired by a professional fitter if one or both tests are failed completely or in part Accessories HWC Homewave Control Box HWC Web service software HWC BERNAL app for IOS HWC BERNAL app for Android B WAY 4 channel radio hand transmitter B WAY 4 channel radio hand transmitter 4 channel radio code loch Antenna with a 6 00 m coaxial cable 2 channel external radio receiver Aluminium key operated push button IP54 Ceiling pull switch Draw cable for the ceiling pull switch 13 ACCESSORIES Order number B 135 130 part of the HWC Homewave Control Bpx see App Store search term BERNAL see Google Play Store search term BERNAL BY 135 104 BY 135 105 B 161 47 will be available soon B 260 58 will be available soon will be available soon 161 15 surface mounted B 161 16 under the plaster B 161 21 B 161 23 Module Residential communal garage will be available soon Green light Red light Caution light 24 V 15 W Flashing light 230 V 15 W One way photocell 10 m range Photocell with reflector Wichet door contact Safety edge 8 2 k Ohm Flow strips Rail extension 1 00 m Rail extension 2 00 m Rail extension 3 00 m Push rod extension Additional locking set for the sectional door Additional loching set for the sectional door Sectional door fittings Swing doors fittings Curved door arm Key l
62. otor Hall sensor cable Equipment put on at the works DEBUG DOWNLOAD Yes Yes N N Manufacturer data interface Equipment put on at the works DOWNLOAD RADIO Yes Yes N N Manufacturer data interface Equipment put on at the works T Yes Yes Terminal max 1 0 mm Transformer primary L 230 V AC Equipment put on at the works T Yes Yes Terminal max 1 0 mm Transformer primary Equipment put on at the worhs N Yes Yes Terminal max 1 0 mm Network neutral conductor N Equipment put on at the worhs L Yes Yes Terminal max 1 0 mm Network phase L 230 V AC Eguipment put on at the works Earth Yes Yes Terminal max 1 0 mm Network Protective Earth Eguipment put on at the works Earth Yes Yes Blade terminal Protective earthing of the base plate Eguipment put on at the works 24 V Yes Yes Terminal max 1 5 mm Transformer secondary 24 V Eguipment put on at the works RT Yes Yes Blade terminal Motor cable red 24 V DC Eguipment put on at the works GN Yes Yes Blade terminal Motor cable green O V DC Eguipment put on at the works Multi segment display Yes No Multi segment display Menu and error displays see programming manual G 402 ON Yes No LED green Ready indications see programming manual G 402 F Yes No LED red Fault displays see programming manual G 402 MENU Yes Print button menu command SCROLL Yes No Print button Drowse command ENTER Yes Print button Confirm command START Yes Print button Otart command LEDI
63. packaging damage or recogni sable damage to the housing engine shaft drive rail carriages push rods door fittings power networh cable fastening materi als or parts of these components may not be installed on safety grounds 3 1 1 CONDITION OF THE DOOR AND THE INS TALLATION SITUATION The garage door drive many only be mounted on garage doors when in a technically perfect condition the door should be che cked completely in particular springs rollers roller holders cables and hinges for wear and damage Also check all faste nings and screw connections for stability and strength Check for ease of movement and weight compensation of the door leaf manual hand operation of the door must be possible without any difficult over the whole path traversed by the door the door must not start moving autonomously from the end positions Door Open Door Closed the door must not if it has been stopped in some arbitrary intermediate position run on open or close autonomously 3 ASSEMBLY Do not use the door anymore and have it repaired by a gualified engineer before assembling the garage door drive if there deficits established concerning damage wear or ease of movement Installation situation The minimum clearance between the upper edge of the door measured at the highest door running point TLP and the ga rage roof must be at least 35 mm Open the door once fully and close it again to determine the
64. plink to the internet HWC web service software and compatible peripheral device tablet laptop PC are necessary 9 3 OPERATING MODE The garage door drive can be driven in pulse repetition mode or in operation with automatic closing Pulse repetition Standard operating mode with an established sequence of commands Start Stop Change direction Automatic closing The door is closed automatically after an ad justable time with additional safety equipment photocell contract Automatic closing may only be used in combination safety edge 29 Event Command START Command VENTILATION Triggering safety elements to terminals L Triggering safety elements to terminals NOT Obstacle force cut off Power supply re established after a power failure BERNAL TORANTRIEBE 9 4 OPERATING CONDITIONS during the door status End position Door Open End position Door Closed Opening gt Door Open Opening gt Ventilation Closing End position Ventilation End position Door Open End position Door Closed Opening gt Door Open Opening gt Ventilation Closing End position Ventilation End position Door Open End position Door Closed Opening Closing End position Ventilation End position Door Open End position Door Closed Opening Closing End position Ventilation Opening Closing End position Door Open End position Door Closed Opening Closing End
65. r as sembly of the drive The set up to programme the paths and the force curve as well as programming programming teaching in of radio hand transmitters may only be performed inside the garage All possibly attached safety elements and the integral obstacle detection force cut off of the garage door drive are NOT EFFEC TIVE during programming of paths and the force curve Ensure that no persons can find their into the area of movement of the machine door during programming of travel paths and the force curve To finalise the commissioning provide perform checking pro duct documentation the manufacturer declaration operator user briefing and training as well as handing 2 3 6 ALTERING THE MACHINE I General danger of injury to persons and damage to equipment IF the mechanical components of the door are defective actu ation of emergency release of the drive can lead to immediate dropping down of the door After commissioning the machine no alteration of the setup of the machine may be made these would additionally require sa fety equipment to be installed by a professional fitter Alteration of the setup of the machine connections or compo nents of the machine may only be undertaken by a professional fitter A renewed set up must be performed after every change made to the machine to ensure that the correct function of the obstacle detection force cut off is secured over the renewed program ming of the force cur
66. r opening and closing cycle the control cable must neither tension up nor hang loosely Test the function of the emergency release system Surround the overhanging end with adhesive or something si milar and cut off 3 2 7 ASSEMBLY OF THE INNER EMERGENCY RELEASE SYSTEM optional equipment Fasten the cable 1 firmly on the emergency release lever with hnots a Push on the cable bell 2 and cable clamp 3 b Perform fixing of the cable clamp so that the lower edge of the cable bell is at least 180 cm above the floor c Cut off any projecting remains of the cable on both sides After completion of the assembly worh put on the drive cap and tighten in place by turning clochwise BERNAL TORANTRIEBE 3 2 8 MANUAL FUNCTION TEST After assembly of the garage door drive ensure with 2 3 ma nually actuated opening and closing processes that the func tion of the door was not impaired by the assembly see also 3 1 1 Check condition of the door Actuate the emergency release system in the garage and move the door by hand The pulley engages for every movement over the drive dog and is respec tively released through further actuation of the emergency re lease system 3 2 9 ATTACHING THE WARNING SIGNS Permanently fix the warning label which refers to danger of get ting caught in the door and to regular checking of the obstacle detection on clearly visible place or near firmly fixed on moun ted control
67. rference on an AC mains connection from harmonic currents and intermediate harmonics including interference sources transmitted by lines from signal transmission to electrical low voltage power networhs DIN EN 61000 4 11 2005 02 Electromagnetic Compatibility EMC Part 4 11 checking and measuring processes checking the resistance to interference from voltage dips short term interruptions and voltage fluctuations DIN EN 61000 4 5 2007 06 from voltage surges DIN EN 61000 4 2 2001 12 static electricity ESD DIN EN 61000 4 4 2005 07 electrical interference factors burst Electromagnetic Compatibility EMC Part 4 5 checking and measuring processes checking the resistance to interference Electromagnetic Compatibility EMC Part 4 2 checking and measuring processes checking the resistance to discharge of Electromagnetic Compatibility EMC Part 4 4 checking and measuring processes checking the resistance to quich transient 37 BERNAL TORANTRIEBE The special technical documentation was created according to Annex VII B The person authorised to compile the relevant technical documentation is the Managing Director of the abo ve mentioned manufacturer IF this incomplete partial machine is brought together with ano ther incomplete partial machine plant or machine to produce a final product machine according to the Machine Directive 2006 42 EC or installed then commissioning of the final pro duct m
68. river a and pull out the belt connector jacket 2 b take the toothed belt out of the belt drive dog 3 c Shorten the toothed belt using a side cutter to achieve the re quired length Insert the toothed belt according to the preformed mount with 6 teeth into the belt drive dog Push on the belt connector jachet and fix in place with the se curing screw The securing sleeve must sit exactly Toothed belts as well as parts of the drive dog must not be lubricated to simplify the work process Mount the rail as described from Picture 7 I PROFESSIONAL EXTENSIONS 4 ELECTRICAL CONNECTIONS 2 3 1 2 3 2 2 3 4 2 3 5 2 3 6 2 3 7 NY Observe the notes on routing cable provided under 2 3 4 Only use original accessories released by the ma nufacturer Connections which mahe it necessary to perform pro N gramming can only be performed AFTER the first set up of the paths and the force see 5 Acceptance testing of the housing cover and the drive hood is essential for connecting accessories first pull out the power plug and secure it against plugging it in again Unfasten the drive cap anticlockwise and remove it Figure 35 a Unfasten the fastening screw for the drive cover Figure 35 b and remove the drive cover Figure 35 c The covers on the 230 V AC area of the control board see Fi gure 4O should never be removed The terminal strips on the accessories can be plugged in not ante
69. s We recommend having the first cheching report produ ced at the time of commissioning by a competent person Important information for the owner operating company of the machine The inspection book is a component part of the product do cumentation and should be kept in safe keeping Ensure that every person commissioned to perform checking servicing or repair work can have access to it We recommend providing at least the cheching servicing inst ructions as well as the handling and or operating instructions for all components including all manufacturer declarations to gether with this inspection book CONTENTS ALI DETAILS OF THE OPERATING COMPANY AL2 SPECIFICATION MACHINE DATA AL3 DECLARATION OF INCORPORATION Al 4 CHECKING REPORT AL5 HANDOVER REPORT The machine should be checked at specified regular intervals by a competent person for a safe condition according to EN 12635 Checking reports should be stored in safe keeping to gether with the product documentation Important information for the competent person professional fitters entrusted with checking servicing or repair work The checking and servicing instructions for the garage door the garage door drive as well possibly for other components on the machine should be observed IF any deficits are discovered during checking the machine Should be taken out of action totally shut down and repaired by a professional fitter The machine may only be commissi
70. s engaged if necessary in the pulley for unloching see Pic ture 13 BERNAL TORANTRIEBE Place the locking element 1 as shown on the end ofthe track Pull the locking bolt 3 of the guide roller unit through the lo cking element put the locking spring 2 with its washer on to the locking bolt and with the washer and self loching nut IF the nut does not fit toothed belt chain seems too short check that the toothed belt chain is sitting cleanly on the gui de roller and the toothed belt pulley chain pinion and check the correct seating of the locking Do not yet fully tighten the toothed belt or chain b note Figure 11 and Figure 12 To facilitate fitting the drive head the toothed belt should be tensioned after fitting the gate door attachment bracket Fi gure 29 When tensioning a toothed belt observe ensure the correct tension is set by means of a slight finger pressure in the midd le of the rail The tensioning spring must not be fully pressed together Press the lever for emergency release system on the pulley and pull the pulley from the drive dog Check for ease of movement of the pulley over the full path tra versed by the door Lock the pulley again with the drive dog pull over and position pulley in the middle of the rail 3 2 2 INSTALLATION OF THE RAIL ON THE CEI LING Measure the door width and trace the middle of the door on the upper edge of the d
71. screws and serrated lock washers 3 2 5 MOUNTING THE DOOR FASTENING BRACKET Mark and pre drill the drill holes Place the gate door attachment bracket on the top edge ofthe gate door b and fix it firmly to the gate door with a total of 4 washers and 2 screws Unlock the slide a Fix the gate door attachment bracket to the push in ac cordance with Figure b It is essential to insert spacing sleeve 12 Lock the slide 3 2 6 ASSEMBLY OF THE OUTER EMERGENCY RELEASE SYSTEM Connection of the outer emergency release system is essential if there is no access point and escape route apart from the rage door If there is no adeguately stable inner turning hand le present on the door then an emergency release plug in key lock accessory should be installed Apply a drilled hole to the side of the handle which will be tur ned downwards for actuation a Lead through a Bowden cable 1 behind through the emer gency release lever and drilled hole for the push rod bolt 2 to wards the front Pull on the Bowden control cable sleeve c Pull the Bowden cable sleeve with the Bowden cable over the holder in the door fastening bracket to the front in a slight bow without a loop a Shorten the Bowden cable sleeve using a side cutter if necessary Lead the Bowden cable through the inner rotary handle b and fix firmly in place using a cable clamp c Check during a complete doo
72. se error 16 is signalled by means of perform the cheching by operating competent company person Triggering acc chapter 12 2 Monthly Annually Checking acc EN12445 Annually Test through triggering for example use Monthly Annually a brush or something similar Optical cheching Monthly Annually Test through triggering Monthly Annually Optical manual checking gt Annually Optical cheching Annually Annually Optical checking Annually Optical cheching Annually Annually Actuation Annually Manual checking Annually Annually Optical checking Annually Optical manual checking __________ Annually Optical manual checking __________ Annually Optical manual checking _________ Annually Optical manual checking _________ Annually Optical manual checking __________ Annually Optical manual checking Annually Optical checking wenn Annually Optical checking Annually Optical checking gt ___ ______ Annually Optical manual checking __________ Annually Optical manual checking __________ Annually Optical manual checking _________ Annually Optical checking ooe Annually Optical manual checking __________ Annually Optical manual checking __________ Annually Acoustic optical inspection Annually Optical checking Annually Optical checking Annually Optical checking re Annually The door and garage d
73. se put a cross against the relevant items taken place after finishing all installation and setting up work taken place in an operable condition after full final checking and function testing taken place in a deficient condition The owner operating company please put a cross against the relevant items was instructed in safe operation of the machine was advised about checks which he should make regularly was advised about his duty to have the machine checked regularly by a competent person The product documentation was handed over including please put a cross against the relevant items Assembly manual s Operating manual s Servicing cheching instruction s Inspection book Manufacturer declaration Declaration s of incorporation First checking report other Place date eo For the fitter assembly company For the owner operating company Name L Name 01 Signature EOE EE EE EE EE ES Signature ANNEX A2 PROGRAMMING MANUAL G 501 rating manual for the garage door drive should be obser tions and parameters in the menu can be obtained from ved for all changes made to the works settings the assembly and operating manual for the garage door drive For an appropriate cross reference to the respecti The safety instructions given in the assembly and ope S Detailed information about the programmable func The attached safety equipment is NOT EFFECTIVE
74. the suspension bracket flush with the lower edge of the middle suspension d Put the rail on again Saw off and deburr the suspension brachet and fasten accor ding to the figure On safety grounds always place the saw cut significantly below the suitable elongated hole for the fastening w o fig Swivel the rail on the ceiling a and support Chech alignment using a spirit level Figure 23 and correct if neces sary Check the alignment of the rail based on the previously traced middle of the door leaf b Trace the drilling holes through the suspension bracket c Then lay the rail on the floor and cover it to protect it against drilling dust Drill the holes a and clean the area if necessary use diffe rent drill diameter according to a suitable fastening material Insert the dowel b swivel the rail on the ceiling and tightly fas ten down using suitable fastening material c BERNAL TORANTRIEBE 3 2 4 ASSEMBLY OF THE HEAD OF THE MOTOR Release the drive cap by turning it anticlockwise and remove a Align the motor head bring the front fastening of the drive head 1 in the ceiling to the second mount 2 for the drive head mount b and put on the drive head c secure the drive head against falling IF the drive head does not fit immediately on the rail Turn the toothed belt pulley chain sprocket slightly and try again Fasten the motor head in place using M8x25 cheese head
75. tion for damages in particular also for subsequent damages are exclu ded from the warranty Submission of copies of the purchase receipt as well as a properly kept inspection book is prerequi site for mahing a claim under warranty 5 Items which are also excluded from the warranty are dama ges resulting from Improper use or use assembly commissioning connections servicing repair worh use or operation of the door garage door drive or accessories which is not according to instructions gi ven in the assembly and operating manual destruction mahing illegible removal or loss of the type plate warning signs or product documentation or parts thereof changes made on the garage door drive including use of re placement materials components in as far as this has not ben cheched by us and expressly released in writing negligent or wilful damage or destruction use of an unsuitable construction base or deficient building worhs which do not fall within the area of our responsibility Rre water influence of extreme environmental conditions chemical electrochemical or electrical influences in as far as these are not foreseeable according to the expected use natural wear and tear Status November 2012 16 TECHNICAL DATA G 501 80 Weight in kg 17 Tensile or compressive force 800 Opening speed in 5 ca 18 Max motor power in W ca 110 Motor type Materials uses Plastics steel Max
76. to pulling in of the body s extre mities and objects Do not hang with the weight of one s body on the cable for the emergency release system Do not fasten any objects to the cable for the emergency re lease system or other components of the door drive On all garages without a separate second entrance an outer emergency release system must be installed in order to allow access to the garage also in the case of a power failure or tech nical defect When using an inner emergency release system draw cable on the emergency release lever of the pulley this must be placed at least 180 cm above the floor 2 3 SAFETY INSTRUCTONS FOR ASSEMBLY COMMISSIONING SERVICING REPAIR WORK DISASSEMBLY 2 3 QUALIFIED SPECIALIST PERSONNEL General danger of injury to persons and damage to equipment due to a lach of specialist Rnowledge Assembly commissioning servicing repair worh disassembly may only be performed by a professional Ritter 2 3 2 ACCIDENT PREVENTION General danger of injury to persons and damage to equipment due to a lach of knowledge about accident prevention regulati ons as well as measures The valid national work protection and accident prevention regulations must be observed for all worh done on the garage door drive as well as the machine 2 3 3 FASTENING THE DRIVE AND FASTENING MATERIAL Danger of injury to persons and damage to equipment due to falling down At the installation site the lintel and
77. ust not touch each other 5 INITIALISATION SET MENU 2 2 1 2 3 1 2 3 2 2 3 5 2 3 6 5 PREREQUISITES The set up must tahe place inside the garage in order to have access to the drive if a fault occurs Assembly must be fully completed and the manual function test 3 2 8 must be performed successfully The carriage must be loched in the drive dog Only for the version of the device without a display acceptance testing of the drive hood is essential for performing the set up Figure 34 the covers on the 230 V AC area of the control board see Figure 40 should never be removed 5 2 SET UP OF THE GARAGE DOOR DRIVE The attached safety equipment is NOT EFFECTIVE du A ring set up The automatic obstacle detection force cut off is NOT EFFECTIVE during set up Perform the set up on the basis of the programming ma N nual after you have informed yourself about the general processing sequence from the following information IF the set up is opened then the points 5 4 Programme paths and 5 5 Programme the force curve must be executed one af ter the other and must be fully completed Breahing off during set up leads to a restart of set up This set up setting can only be interrupted by pulling out the power plug The integral drive light is deactivated during set up Set up for first commissioning or after Reset parameters to the factory settings Create a power supply by plugging in the power
78. ve After making the changes all safety relevant components and Functions should be checked for orderly Function All changes to the setup of the machine connections or com ponents of the machine must be documented in the inspection book with exact details of the date components involved the person doing and the company doing the work changes of owner operator details must be documented in the inspection book Changing the closing force adjustment can lead to personal in jury Therefore increasing the clamping force may only be performed by a competent person After adjustment compliance with the normative values with suitable measuring device must be de monstrated and documented 2 3 7 SERVICING REPAIR I General danger of injury to persons and damage to equipment Repair work may only be undertahen by a professional fitter The power plug must be tahen out and secured against plug ging in again before performing any worh on the machine with the exception of programming the drive IF the mechanical components of the door are defective actu ation of emergency release of the drive can lead to immediate dropping down of the door One must not reach into unsecured moving parts of the machi ne while performing servicing worh Wear parts must be replaced according to instructions issued by the manufacturer Only parts which have been released by the manufacturer may be used for repair worh 2 4 SAFETY IN
79. well as the garage door drive Model designation Serial No Manufacturer Order No Operating mode as well as the safety eguipment 1 Model designation manufacturer 2 Model designation manufacturer 3 Model designation manufacturer 4 Model designation manufacturer 5 Model designation manufacturer as well as the accessories 1 Model designation manufacturer 2 Model designation manufacturer 3 Model designation manufacturer 4 Model designation manufacturer 5 Model designation manufacturer 6 Model designation manufacturer Miscellaneous points Pulse repetition controlling Automatic closing Changes 42 Al3 DECLARATION OF INCORPORATION according to EG RL 2006 42 EG Annex The manufacturer hereby declares Company name 1 Company name 2 Street name house number Postal code place of the machine Model designation Serial No The basic safety and health protection requirements of the following EC directives are used and complied with please put a cross against the relevant items Machine Directive 2006 42 EC Directive 2004 108 EC Low Voltage Directive 2006 95 EC Building Products Directive 89 106 EC The following standards amongst others are used and complied with please put a cross against the relevant items EN 13241 1 EN 12445 EN 12453 EN 12604 EN 12605 111111 The speci

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