INSTALLATION MANUAL
Contents
1. 450 gt OIL HYDRAULIC OPERATOR FOR GARAGE DOORS WITH COUNTERWEIGHTS IN CONFORMITY WITH EN 12445 EN 12453 STANDARDS FADING the gate opener APROLI 480 OIL HVDRAULIC OPERATOR FOR GARAGE DOORS SECTION VIEW OF THE OIL HYDRAULIC OPERATOR WITH LAMP AND COVER UPPER SECTION __ ______ SUPPORT LIGHT DIFFUSION a COVER SCREW SEAT FOR FIXING THE __ COVER UPPER SECTION N OIL CONTAINER ELECTRIC MOTOR TOP END CAP FADINI OIL __ A 15 BY AGIP HYDRAULIC LOBE PUMP S N TWO WAY LOCKING TT TT TNS T PRESSURE VALVE C T ASSEMBLY ET PISTON SLEEVE azm m GEARBOX es __ HOUSING ang TOOTHED SHAFT SPACER BEARING at GEAR TEETH td covER SCREW SEAT FOR FIXING POZ si THE COVER BOTTOM END BOTTOM SECTIIN REFLECTOR 230 V 25 W LAMP 0 ELECTRIC TERMINAL COVER ELECTRIC TERMINALS mr A BLEED SCREW 0 33 HP ELECTRIC MOTOR OIL RESERVOIR iy Gumi donis dum sg OIL A 15 BY AGIP ua MANUAL RELEASE LEVER ae TWO WAY LOCKING T VALVE ASSEMBLY 7 FADINI OIL A 15 BV AGIP x2. DOOR SECTION To release Aproli 480 for hand operations it is available a device as described above on request Turn the key sharply this will pull the cord and the lever open As an option you can fit the door with a service hatch Pic 13 s d DOOR FROM OUTSIDE There are two solutions to get access to the operator release lever for hand operations of the door Either a lock is fitted at a suitable distance from the release lever to which it is connected by a steel flexible cord as in Pic 13 12 cm x 12 cm lockable hatch is provided and fitted to allow a hand to pass from outside to inside and release the lever B The electric cable which supplies power to the motor pump is connected by means of terminals which are located above the oil container next to the earth screw connection The cable must be led along the door to the point where the telescopic arm is welded to the bar It is recommended that the cable is allowed to dangle free by 130 cm so that the door can go fully up to the end of the permitted stroke EARTH SCREW CONNECTION POSITION OF THE CLOSE APROLI 480 WITH COVER ELECTRIC CABLE TO DANGLE FREE LENGTH 1 30 METRES PIC 14 lt COURTESY LIGHT EXTRA CAPACITOR IN CASE OF POWER SHORTAGE OR TO IMPROVE THE POWER OF THE OPERATOR WHEN HEAVY DOORS ARE INVOLVED TO REVERSE THE DIRECTION OF THE SHAFT ROTATION SWOP WIRES ROUND No 10 AND No 12 DO NOT CHAN
3. nis TELESCOPIC ARM OVERLAPPING THE DOOR ARM WHEN aio S THERE IS NO SPACE BETWEEN ARM AND COUNTERWEIGHT FIXING i EXISTING UEM Wh GUIDE ARM a FIXING ON THE OPERATOR IN THE GUIDE ARM OPEN POSITION I Ta ad i 10 e TELESCOPIC ARM 2 OVERLAPPING THE DOOR ARM WHEN THERE IS NO SPACE BETWEEN ARM AND perm COUNTERWEIGHT BRACKET FIXING ON TO THE GUIDE ARM KA 2 LA X CNN NON 6 Once the bracket and the operator have been fixed to the door proceed to temporarily fix the two telescopic arms to the torsion shaft considering that the shaft must be allowed to rotate 5 degrees less than the end of the permitted stroke as further explained in pic 7 END OF PISTON STROKE WHEN NO FURTHER TURNING IS ALLOWED SN HYDRAULIC LOCKING Bp UNLOCKING LEVER ROTATE IN THE ARROW DIRECTION BY 5 mm TO GET 5 PIC 7 lt Rotate the shaft to the end of the permitted stroke by means of pliers Then rotate the shaft back by 5 mm This allows more power to the operator when it is required to close the door Pic 7 Please note the door must be in closed position when this operation is done FIXING PLATE TELESCOPIC ARM LATERAL SUPPORT a TORSION BAR y PIC 8 CLOSED DOOR LATERAL SUPPORT PROVIDED WITH N THE EQUIPMENT Fit the two telescopic arms to t
4. zo d o E gt m KE 5 Sa DE Jo d am TK Sk BI 29 9 I 72 9 gt a ma m 2383 ME 3 3 2 ER gt m o meo L 2275 B moa Pa gt Z z 3 c zi tC 2 BS m mom zm o z m S 4 gt gt o0 oy gt E 5 2 n 4 Elpro 6 exp RADIO CONTACT BUTTON ON THE COVER LID aa EE PC BOARD DRWG 1795 ITIS ILLUMINATED WHEN VOLTAGE IS SUPPLIED KEVSWITCH PRIT 19 16 All the electrical connections to the control panel to be made as per Drawing 1795 Elpro 6 exp having the following features terminals for the keyswitch open stop close photocells safety edge courtesy light remote control to terminals 3 amp 4 where the first pulse opens the door the second stops it and the third re cycles to open or close GARAGE DOOR OPERATOR COMPLETE WITH ALL THE RECOMMENDED ACCESSORIES FOR A GOOD PERFORMANCE 230 VOLTS MAINS SUPPLY 0 03 Amp CIRCUIT BREAKER MIRI 4 FLASHING LIGHT 25 Watts FITTED WITH BIRIO A8 AERIAL PLUG IN RADIO RECEIVER CARD ASTRO 43 SAW ELECTRONIC CONTROL BOX Elpro 6 exp START PUSH BUTTON KEYSWITCH PRIT 19 SAFETY EDGE LOW PROFILE PHOTOCELL TRIFO 11 RECEIVER 25 Watt LAMP OPERATOR APROLI 480 COVER TO PROTECT THE VALVES FIXING BRACKET PHOTO
5. 18 sec Closing Timeof OME omplete e va et 66 sec Complete TESTI LE No 47 hour Annual cycles 8 hours service per day tentes ttt tendente No 159 000 5 CHECKING AND MAINTENANCE To achieve an optimum performance and longer life of the equipment and in observance of the safety regulations it is recommended that inspections and proper maintenance are made by qualified technicians to the whole installation ie both the mechanical and electronic parts as well as wiring Mechanical parts maintenance every 6 months approx Eletronic apparatus and safety equipment maintenance every month IMPORTANT WARNING NOTES Before installing the equipment carry out a Risk Analysis and fit any required device in compliance with EN 12445 and EN 12453 Safety Norms It is recommended to keep to the instructions here outlined Check the specifications on the motor sticker with your mains supply Dispose properly of the packaging cardboard nylon polystyrene through specializing companies Should the operator be removed do not cut the electric cable This must be properly removed from the terminal board in the junction box Switch off the mains switch before removing the junction box cover where the electric cable is terminated All the system
6. BAR LATERAL SUPPORT MAX PRESSURE SAFETY VALVE ver CLOSE GREEN FIXING BRACKET It is recommended to follow the drawings in this manual to install APROLI 480 on to garage doors in order to automate them The operator is designed for the installation in the centre of the existing door by means of a bracket that is fixed to the door with screws Pic 4 WALL FRAME DOOR JAMB DOOR FRAME _ GUIDE ARM OF THE DOOR EXISTING DOOR Al COUNTERWEIGHT FIXING 7 s CASE AND ROLLER pe GUIDE TUBE PERPENDICULARLY FITTED REINFORCEMENT PLATE 100x5 mm y PIC 4 Should the upper and lower fixing ends of the bracket not coincide with the upper and lower edges of the door it is recommended to rivet screw or spot weld an iron reinforcement plate 100 mm 5 mm thickness vertically across the door so to connect the top and bottom edges of the door as shown in pic 4 TELESCOPIC ARM TO BE 415 PARALLEL FIXED TO THE FIXING PLATE EXISTING DOOR ARM TO WELD ot N 90 80 CLOSED DOOR POSITION APROLI 480 COUNTERWEIGHT CASE 5 lt Once the bracket has been fixed it is to be determined whether the telescopic arms are to overlap the existing door arms or be fixed parallel to them See pic 5 and 6 Then proceed to weld the fixing plates as indicated by the distances in pic 5
7. 100 mm below the door hinge centre line Pic 19 APPLICATION OF APROLI 480 ON TO A DOOR WITH UPPER TRACK FULLY INDOOR UPPER GUIDE COUNTERWEIGHT N COUNTERWEIGHT REINFORCEMENT PLATE E 100x5mm TT LOWER ROLLER SLIDING IN TOi THE LATERAL PERPENDICULAR for ae CASING eer 20 UPPER FIXING BY THE SIDE OF THE DOOR SLIDING GUIDE WALL FRAME WARNING LAMP ON STARTING __ WITH RADIO AERIAL UPPER ROLLER l FOR HORIZONTAL C UPPER TRACK For the installation of Aproli 480 on to garage doors with upper track follow the same instructions as explained before the shaft ie the torsion fulcrum must coincide with the centre line of the door right in the middle between upper and lower guide rollers See Pic 20 OIL FADINI A 15 BY AGIP STICKER FITTED TO THE OIL TANK UNSCREW BY ONE TURN TO BLEED AIR OUT OF THE OIL TANK IMPORTANT AFTER UNDO BY ONE TURN INSTALLATION S APROLI 480 21 lt Please note once Aproli 480 has been fixed unscrew the air bleed screw by one turn This screw is fitted on the cap of the oil container where the voltage supplying cable is led to the motor Pic 21 Should the operator Aproli 480 be removed for maintenance or repairing tighten the screw S to prevent oil from coming out during handling 30X UNSCREW LAMP REFLECTOR ELECTRIC CABLE ELECTRIC MOTOR ELECTRIC CABLE SAFETY EDGE LAMP VOLTAGE SUPPLY PR
8. CELL TRIFO 11 PROJECTOR RADIO TRANSMITTER ASTRO 43 TWO BUTTONS PIC 17 lt SPECIAL GARAGE DOORS SAFETY SWITCH SINGLE PHASE Elpro 3 1 1 30 ELECTRIC CABLE L TO DANGLE FREE E REINFORCEMENT PLATE i 100x5 mm PIC 18 lt When very large doors are involved with a service door in the middle it is recommended to install two operators Aproli 480 on to the door sides without connecting the shaft inner ends Fixing dimensions and measurements are as explained before in the previous application drawings It is also recommended to fit the service door with a safety microswitch as shown in pic 18 When two operators are required for one door it is recommended to install the control panel Elpro 13 CEI and one pair of photocells Trifo 11 These are to be fixed on to the counterweight case 40 cm from ground level APPLICATION OF APROLI 480 ON A JACK KNIFE DOOR Elpro 6 exp UPPER HINGES STEP BY STEP 80 100 mm CENTER 2 HINGES FA sal ELECTRIC CABLE LOOP LENGTH 1 30 m__ 2500 SLIDING GUIDE FOR ROLLER REINFORCEMENT PLATE 100 x 5 mm ROLLER WITH p a AA S SLIDING GUIDE 7 y gt PIC 19 For jack knife doors the same instructions apply as for single panel doors as explained in the previous pages Only please note that with articulated doors as the above type it is recommended to fix the operator so that the shaft and the torsion bars are 80
9. ESSURE SWITCH WITH PRESSURE CABLE SWITCH 22 NEVER CUT THE ELECTRIC CABLES It is most important that the electric cables are removed from their terminals by loosening the fastening screws Never cut the electric cables Also make sure that the 230 V mains switch is off before removing the cables See page 11 pic 17 Only by keeping to these fitting instructions a reliable installation and correct performance of the equipment can be achieved The installation is fully under the responsibility of the installation agent even if only Fadini products have been used as indicated in this booklet It is advisable that the system is installed in full compliance with these instructions and in observance of the existing laws for automatic gate equipment The information specifications and drawings contained herein are subject to any change that the manufacturer considers as needed OIL HYDRAULIC OPERATOR FOR GARAGE DOORS WITH COUNTERWEIGHTS MPROLI 480 TECHNICAL SPECIFICATIONS APROLI 480 FIXING 44 bes Arnou 49 BRACKET Via Mantova 177 A 37053 Cerea VA Italy Tel 0442 330422 r a Fax 0442 331054 DOOR OPERATOR 2 PHASE 2 LINEAR DESIGN 330 0 33 APROLI 480 239 TA 18 ELECTRIC in 1350 Hz 50 s TERMINAL 3924 uF 125 OUTPUT Protection Standards IP 55 Max working pressure 4 MPa 40 Bar OIL FADINI A15 BY AGIP C MADE I
10. GE No 11 1 ELPRO6 exp PIC 15 It is essential to make sure that the shaft rotates in the required direction during the first running test Should it rotate in the opposite direction change wire No 10 with No 12 Pic 15 ELECTRICAL WIRING DIAGRAM OF THE OIL HYDRAULIC GARAGE DOOR OPERATOR APROLI 480 TO THE ELECTRONIC CONTROL PANEL BIRIO 8 AERIAL wy TRANSFORMER LED ON VOLTAGE SUPPLIED RADIO CONTROL PLUG IN CARD SUPPORT 24 V OUTPUT 1 CHANNEL 630 mA MOTOR RUN OPEN amp CLOSE TIME CAPACITOR DIP SWITCH DWELL TIME e OFF ASTRO 43 2 RADIO RECEIVER PLUG IN PC BOARD gt 3 2 gt x m ceo ceo co D gt D c m gt ay apis no Jeuuojsuen lel IXNE ue amp inuenb ay uey pauinbai ag 920 0 jo aou PJNOUS El fa 8 2 A 340 JILVINOLAV IN3S NO DNISOTI 34 DILVIWOLAW 440 dINVI DNIHSVIH NO SALANIIN OML AS3LYNOI 33INVUVnb9 ON SIIHOSS329V INIGV4 AINO S31V9 31578340 01 031531 SI T3NVd SIHL TIHM 3LON N ma On EC m mz 98 LS S lt gt 05 4 v d Se lt BE a za r co d zm mm zm lt di I 54 a Za zz 2z 22 5 5 3 8 zi 5 Fs SB zo
11. N ITALY DATA STICKER ELECTRIC MOTOR 4 LAMP AND LAMP REFLECTOR 5 _ PROTECTION COVER LIGHT DIFFUSION TOP COVER beg 7 BOTTOM COVER PIC 23 lt OIL HYDRAULIC PUMP ELECTRIC MOTOR PUMP TOW a L A 1 10 Amin output 0 24 KW 0 33 HP Working pressure 4 4 0 4 2 20 bar Supply voltage 230 V Maximum pressure eerte 4 MPa 40 bar Frequency tnnt 50 Hz Working temperature ssse 20 C 80 C Absorbed 2 tnt 330 W Opening UMa nente 18 5 Absorbed Current s m sese 1 8 A Recommended door size sse Jm Lapacitoti usua bd epe ie ie ttd Ras Ert duas 12 5 uF Shaft rotation max 205 Motor revolution eene 1350 r p m Hydraulic Olli tne ed oil Fadini A15 by Agip Protection Standard sse IP 55 Static weight of operator 10 5 Kg Motor rated torque 1 3 Nm Weight of Aproli 480 with 24 Kor CaP eo pie o eie iere gerer 230 V 25 W Max curte tpe te ete eee 3924 Nm Intermittent service issaraen tette S3 Max g te tee etr rte entia ance 150 Kg PERFORMANCE DUV 18 sec Opening 30 sec Dwell
12. QD LL i piston WITH STEEL INSERT SHAFT SUPPORT E FADINI OIL A 15 BY AGIP NL CYLINDER END CAP INSTRUCTIONS FOR THE INSTALLATION OF APROLI 480 TO A GARAGE DOOR WITH COUNTERWEIGHTS 2 WEATHER STRIP DOOR HANDLE le TA DOOR JAMB COUNTERWEIGHT WHEEL 7 GARAGE DOOR GUIDE ARM D MA fik S TELESCOPIC ARM LARA LATERAL SUPPORT COUNTERWEIGHT WEATHER STRIP APROLI 480 COUNTERWEIGHT CASE WITH COVER ff M BOTTOM DOOR WHEEL ilie V EATHER STRIP T 11 100x5 mm REINFORCEMENT L To JA Fixing M PLATE TO BE FIXED TO 0 THE DOOR FRAME No change to the existing door is required for the installation of this operator Automatic or semi automatic operations Hand operation can be made possible by releasing the system through the lever B both from inside or outside the building Pic 1 ESSENTIAL COMPONENTS FOR THE APPLICATION OF THE OPERATOR ON TO A GARAGE DOOR HAVING COUNTERWEIGHT PIC 3 gt TERMINAL BOARD COVER TELESCOPIC ARM FA TELESCOPIC ARM TRANSMISSION BAR WITH SHAFT FITTING SLEEVE SQUARE HOLE WELDED TO IT X MAX PRESSURE SAFETY VALVE A OPEN RED TRANSMISSION
13. he torsion bars and make sure that they are perfectly perpendicular to them at the same distance from the door Adjust the two supports to achieve the above and put some wooden spacers to bring the lateral supports to the required distance A spirit level will ensure that the torsion bars are perfectly horizontal See pic 8 The lever B must be in the released position TELESCOPIC ARM WITH SLIDING BAR CUT TO MEASURE CIRCULAR WELDING _ FIXING PLATE TELESCOPIC ARM WITH SLIDING BAR CUT TO MEASURE AND WELD LATERAL SUPPORT TORSION BAR WITH SLEEVE PIC 9 lt Fit the two telescopic arms and the torsion bars in the correct position and make sure that they are levelled and parallel door in the closed position Partially weld the torsion bars to the lifting arms and operate the door by hand Verify that it can open fully in a quiet and smooth way The lever B in the released position Pic 8 Once satisfied that the installation is correct and smooth remove the two torsion bars and the sliding bars in order to firmly fix them by welding all around Pic 9 IN THIS POSITION THE DOOR MUST BE WELL BALANCED SHOULD IT NOT ADD SOME EXTRA COUNTERWEIGHT FIX THE COVER 77 ONLY AFTER COMPLETING THE INSTALLATION PIC 10 lt A good test to verify how well balanced the door is in both directions ie lifting and lowering is to position it 45 deg
14. must be earthed by using the yellow green wire marked by its specific symbol Itis recommended to read the regulations suggestions and remarks quoted in the booklet Safety Norms FADINT the gate opener Made in Italy The growth of MECCANICA FADINI has always been based on the development of guaranteed products thanks to our TOTAL QUALITY CONTROL system which ensures constant quality standards updated knowledge of the European Standards and compliance with their requirements in view of an ever increasing process of improvement The CE mark certifies that the operator conforms to the essential requirements of the European Directive art 10 EEC 73 23 in relation to the manufacturer s declaration for the supplied items in compliance with the body of the regulations ISO 9000 UNI EN 29000 Automation in conformity to EN 12453 EN 12445 safety standards EUROPEAN MARK CERTIFYING CONFORMITY e BE UNE CONFORMITY ides ARENE T CETA e EN 12453 EN 12445 STANDARDS e CEI EN 60204 1 STANDARDS e WARRANTY CERTIFICATE ON THE CUSTOMER S REQUEST meccanica FA l b M Distributor s box akse TENT The manufacturers reserve the right to change the products without any previous AUTOMATIC GATE MANUFACTURERS notice and are not liable for possible damages to people and properties Via Mantova 177 A 37053 Cerea Verona Italy Tel 39 0442 330422 r a Fax 39 0442 331054 e mail info fadini net www fadini net
15. rees from ground level as shown in picture 10 Add counterweight to improve running smoothness and balance if required The two safety pressure valves are identified by colours A Open is red C close is green They are located in the front of the motor pump unit easy to reach for setting operations in order to meet the power requirements Pic 11 Once the valves are set you can fit the cover and the other 11 mr S AIR BLEED MAXIMUM accessories Pic 10 PRESSURE RELEASE LEVER VALVE OPEN TURN IT RED IN COLOUR A ANTI CLOCKWISE MAXIMUM SN PRESSURE VALVE CLOSE L GREEN COLOUR C E The setting of the safety pressure valves is to be done so to achieve the exact amout of power required to safely operate the door The more you turn the screw clockwise the more you increase the power of the operator Try RELEASE D LEVER B OPEN RUBBER STOP ON THE OUTSIDE OF THE DOOR RUBBER STOP RECOMMENDED STARTING POSITION BEFORE CLOSE CYCLE RUBBER STOP PIE 12 4 The highest power is required to start the close cycle Therefore it is recommended to fit rubber stops to the door This will cushion the door at the end of the up stroke and will keep the door inclined by 5 degrees for a better start See Pic 12 y Pic 13 RELEASE LEVER LOCKABLE l HATCH DOOR RELEASE CORD
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