Summary of Contents for Aumuller ferralux KSA Series
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Mounting Instructions in accordance with machine directive 2006/42/EG (annex Chain drive KSA xxx in 24V DC and 230V AC ferralux ® 2011W03...
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Manufacturer Steinerne Furt 58a • 86167 Augsburg Postfach 52 12 61 • 86095 Augsburg Tel.: +49 (0)821 27 09 30 • Fax: +49 (0)821 70 98 42 www.ferralux.de • info@ferralux.de Product description Translation: 19.01.2011 We are here for you: Monday to Friday from 8.00 to 16.00 and Friday from 8.00 to 12.00. Important note: We are conscious of our responsibility to take great care in the illustration of life saving products with lasting quality.
Table of Contents TD- Documentation Table of abbreviations / Risk assessment - Information transfer / Important safety instruction ..4 / 5 / 6 Certificates / Declaration of incorporation....................7 / 8 Intended use / Application area and range......................9 Suitability of application for windows / flaps in roof area & in facade area ......... 10 / 11 Checks prior to assembly ..........................12 Chain drive KSA xxx 24V DC (detailed diagrams / overview) ...............13 Chain drive KSA xxx 230V AC (detailed diagrams / overview) ..............14...
Risk assessment and information transfer TD- Documentation Risk assessment Start for power-driven casements (machines) in accordance with EN ISO 14121-1 & EN ISO 12100-1,-2 Specification of use, operation and purpose of the window General procedure Identification of dangers Information Risk analysis After the planner has made a risk assessment for power-driven casements and documented same in construction requirements, it is the responsibility of the installer to make another risk assessment and...
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Important safety instructions TD- Documentation Read prior to assembly and keep for life span of drive ! Symbols for safety instructions: Danger of clamping and crushing! Window closes automatically ! Caution / Warning Danger due to During closing and opening the drive stops via its integrated electrical current or external load disconnection (depending on version of drive).
Certificates TD- Documentation Mounting Instruction Chain drive KSA xxx-24 V / 230V 219-100-0-0-1.0.doc Page 7 of 68...
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Declaration of incorporation TD- Documentation EINBAUERKLÄRUNG für eine unvollständige Maschine (nach Anhang II-1B der EG-Richtlinie 2006/42/EG Declaration of incorporation for a partly completed machinery (in accordance with Annex II-part B of EC- Directive 2006/42/EC) (Dokument - Nr. / Document no .: 121-175-0-13-8.0) Hersteller Manufacturer...
Intended use Application area and range TD- Documentation Example with objekt Application principle Application area For electromotive opening and closing of building openings in the facade and roof area. Examples are: top hung project- ing, bottom, top and side hung, vertically and horizontally pivoting windows as well as light domes, flaps and blinds Example: roof area window made of basic materials such as aluminum, plastic or wood.
Suitability of application for windows / flaps in roof area TD- Documentation Roof window systems Symbols explanation very Pyramid Light dome Top hung Bottom hung suitable not so suitable doubtful application Single/Tandem direct (HSK) Single direct (HSK-RA) Single direct (HSK-RA) Single direct (HSK-RA) General range of casement dimensions Single contact directly on HSK...
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Suitability of application for windows in facade area TD- Documentation Facade window systems Tophung projecting Vertically pivoting Horizontally pivot. Side hung Top hung Bottom hung inward inward inward outward outward outward Single direct (HSK) Single direct (HSK-RA) Single direct (HSK-RA) Tandem direct (HSK) Single direct (HSK-FL) Single direct (HSK-FL)
Checks prior to assembly TD- Documentation Attention: Important instructions for safe assembly! Adhere to all instructions! Improper assembly may lead to serious injuries! Storing of drives on construction site prior to Check assembly requirements assembly Application area / window type and the actual constructural situation will result in different drive assembly requirements.
Chain drives type list Force path diagrams TD- Documentation Application / Case of loading 800 to 1000 1000 From stroke preferably for tensile load / From stroke only for tensil load Version Stroke Version Stroke 24V DC 230V AC 1000 1000 1200 1200...
Requirements for assembly TD- Documentation During the assembly of the „ incomplete machine „ Chain drive Typ: KSA xxx – 24V DC & 230V AC KSA 2 xxx – 24V DC & 230V AC conditions Necessary tools the following must be met, to ensure they can be assembled properly with other parts into a complete machine Depending on the particular application, different tools without jeopardizing the health or safety of personnel:...
Scope of delivery / Facing of the drive TD- Documentation editing help (part of profile) KSA – Covering profile Aluminum in E6/C-0 (natural anodized) Assembly on KSA- body / profile clamped and removable with Editing help (parts of profile) ord. no. incl.
All-purpose casement brackets & Casement brackets with profile-specific system TD- Documentation Ø5,5 (x3) Ø6 Ø5,5 (x3) Base plates for F 14 Aluminum Casement bracket F 14 2x t=3mm and 3x t=5mm Aluminum in E6/C-0 ord. no. 524198 with grub screw M6x35 ord.
Mounting brackets TD- Documentation Ø14,5 Ø14,5 Mounting brackets A-1 Mounting brackets B-1 stainless steel V2A stainless steel V2A Assembly on casement (inward) Assembly on casement (inward) or on frame (outward) or on frame (outward) ord. no. 524057 ord. no. 524053 Ø14,5 Ø14,5 Mounting brackets C-1...
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Brackets Sets TD- Documentation Ø5,5 (x3) Ø9 Base plates Set for F M8x16 (x4) Aluminum necessary only for KSA xxx S2 Bracket Set F for casement overlap (FÜ): up 10,5 to 21mm Aluminum E6/C-0 Base plates for F14: Assembly on casement (inward), 2x t=3mm and 1x t=5mm (drive going with) with 4x countersunk-head screws M8x16...
Selection of fastening devices TD- Documentation The selection of appropriate fastening devices and materials is an important prerequsite for the safe and flawless functioning of drives on power-driven windows. Only the following fastening devices and materials are to be used! Prior to beginning with assembly, check size of fastening devices that can be used: size 5! Check in regular intervals that all clamping and mounting screws are firmly seated;...
Type of bracket – Assignment to window type TD- Documentation Applications for types of windows Mounting brackets / sets R & L top-hung bottom hung horizon. pivot side-hung top-hung proje. R & L parallel hinged 27 - 35 on pages Further applications on request roof roof...
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Type of bracket – Assignment to window type TD- Documentation Mounting brackets / sets Applications for types of windows mechanical casement locking R & L top-hung bottom hung horizon. pivot side-hung additional Mounting bracket C-1 necessary locking bar (on site) 123-50-0-1-0 see Assembly instruction Further applications on request...
General installation advices TD- Documentation General adjustment possibilities Soft run pre-tensioned chain chain tension (stud screw released protruding 3,5 mm) (stud screw is screwed in) SW2,5 CLOSE-position factory setting - chain fully pre-tensioned Set pre-tension of chain on site Soft run setting through manual unlocking of chain - only for bottom hung windows - The drive has an electronic path measurement.
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General installation advices TD- Documentation Replacing the cable exit Required: when there is a danger of the cable being sheared off at the bracket during the opening run Protective sleeve Covering cap Open drive on side with cable Feedthrough of cable - Pull covering cap manually out of drive profile - Feed the cable carefully through the new opening - Pull cable completely out of covering cap...
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General installation advices TD- Documentation Prevention of common danger: collision of chain with window profile Bracket Drive Chain Chain Collision Correct application - caused by faulty planning like: 1. Chain stroke (max. opening width) was not adjusted to required minimum - Chain stroke adjusted to min.
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Planning: Mounting brackets A-1 / B-1 / B-2 for inward opening windows / Tandem operation TD- Documentation Tandem operation on bottom hung window / Wing assembly Tandem operation on bottom hung window / Wing assembly Mounting bracket A-1 (Space 45mm) Mounting bracket A-1 ( Space...
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Planning: Mounting brackets A-1 / B-1 / B-2 for outward opening windows / Tandem operation TD- Documentation Tandem operation on bottom hung window / Frame installat. Mounting bracket A-1 ( Space 45mm) junction box 24V DC connection on site Covering Covering profile profile...
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Assembly procedure for Mounting brackets: A-1 / B-1 / B-2 for inward opening windows / Frame installation on HSK TD- Documentation ° ° Screw on casement Mounting bracket A-1, B-1, B-2 - ensure it is parallel to casement edge (data for drill holes see pages 27 & 28) Mounting of bracket sets A-1,B-1,B-2 possible with 2x screws - must be checked prior to assembly...
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Assembly procedure for Mounting brackets: A-1 / B-1 / B-2 TD- Documentation for inward opening windows / Frame installation on HSK Laying in casement profile Route cable on / in casement - the cable must adapt to the pivoting range of the drive (lay with strap) - Cable must be protected against damage such as shearing off, kinking, cracking (e.g.
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Assembly procedure for Mounting brackets: A-1 / B-1 / B-2 for outward opening windows / Frame installation on HSK TD- Documentation Chain Example of calculation Mounting on outward opening top hung windows Mind force path diagrams on page 15 in roof area - check max.
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Planning: Mounting brackets K84-1 / C-1 / E-1 for outward opening windows TD- Documentation Single application KSA / KSA2 : outward opening window Dimension drawing for Brackets K84-1 , C-1 , E-1 left side at the top (mirror image) 230 (KM - 24 V) 306 (KM - 230 V) Output bottom right...
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Assembly procedure for Mounting brackets: K84-1 / C-1 / E-1 for outward opening windows: Frame- or latch and post assembly TD- Documentation on HSK KSA xxx / KSA2 xxx Nullpunkt FG= ? Konsolensatz C und E Mitte Flügelbock bzw. Diese Montageanleitung wendet sich an ausgebildetes Fachpersonal, gr undlegende Arbeitsschritte werden "C"...
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Assembly procedure for Mounting brackets: K84-1 / C-1 / E-1 for outward opening windows: Frame- or latch and post assembly TD- Documentation on HSK ° Screw on casement Mounting bracket K84-1, C-1, E-1, - ensure it is parallel to casement edge data for drill holes see pages 36 &...
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Assembly procedure for Mounting brackets: K84-1 / C-1 / E-1 for outward opening windows: Frame- or latch and post assembly TD- Documentation on HSK Check pivoting range - Drive must be able to traverse freely with connection cable possibly replacing the cable exit In case the pivoting range is being Route cable on frame and / or waler limited by the bracket, the cable entry...
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Planning: Brackets Set D-1 TD- Documentation for inward opening windows Single application KSA / KSA2 inward opening window Dimension drawing for Bracket Set 230 (KM - 24 V) Z-bracket 306 (KM - 230 V) 181 (24 V) 257 (230 V) 1/2 FAB 24V DC 230V AC...
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Planning: Brackets Set D-1 for inward opening windows TD- Documentation Single operation Planning table Bracket Set D-1 Bracket Set D-1 (Space 45mm) FÜ Stroke 350/37° 350/37° 400/33° 400/33° 700/31° 700/31° 800/28° 800/28° 900/30° 900/30° 1000/27° 1000/27° 1200/28° 1200/28° 1300/26° 1300/26° 1600/28°...
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Assembly procedure for Brackets Set: D-1 TD- Documentation for inward opening windows / Wing assembly on HSK KSA xxx / KSA2 xxx Nullpunkt / zero Konsolensatz D-1 Aufkleber für Rahmen Montageanleitung beachten! Bracket set D-1 Sticker for frame Please note assembly instructions! www.ferralux.de Best.
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Assembly procedure for Brackets Set: D-1 for inward opening windows / Wing assembly on HSK TD- Documentation ° ° Screw on casement Mounting bracket - ensure it is parallel to casement edge data for drill holes see pages 43 & 44) Hang drive in mounting brackets - Insert the spacer rings and tighten firmly with M8 countersunk-head screws - Drive must remain moveable between brackets...
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Assembly procedure for Brackets Set: D-1 TD- Documentation for inward opening windows / Wing assembly on HSK Check pivoting range - Drive must be able to traverse freely with connection cable possibly replacing the cable exit In case the pivoting range is being Route cable on frame limited by the bracket, the cable entry must be changed !
Planning: Mounting bracket F for inward opening windows TD- Documentation Ø5,5 Ø5,5 (x3) (x3) Ø6 Ø9 M8x16 (x4) Casement bracket F14 Base plates Set F Brackets Set F Inward opening window Inward opening window Inward opening window Drive going with - Wing assembly Drive going with - Wing assembly Drive going with - Wing assembly max.15...
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Planning: Mounting bracket F TD- Documentation for inward opening windows Single application KSA / KSA2 inward opening window Dimension drawing for Mounting bracket 230 (KM - 24 V) 306 (KM - 230 V) 206,5 (24 V) 282,5 (230 V) 1/2 FAB 24V DC 230V AC Stroke...
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Planning: Mounting bracket F for inward opening windows TD- Documentation Single operation Cable routing Mounting bracket: F (Space 29mm) on casement or integrated in casement profile FÜ Planning table with Mounting bracket: F w/o cable transition with cable transition FAH min. (on bottom hund window) FAB min.
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Assembly procedure for Mounting bracket: F TD- Documentation for inward opening windows / Wing assembly on HSK KSA xxx / KSA2 xxx linke Außenkante - left outside edge linke Außenkante - left outside edge linke Außenkante - left outside edge linke Außenkante - left outside edge linke Außenkante - left outside edge linke Kante Flügelbock...
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Assembly procedure for Mounting bracket: F for inward opening windows / Wing assembly on HSK TD- Documentation ° ° Example on flush-designed casement flush (FÜ=0mm) Screw on casement mounting bracket on left and right side - ensure it is parallel to casement edge data for drill holes see pages 49 &...
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Assembly procedure for Mounting bracket: F TD- Documentation for inward opening windows / Wing assembly on HSK Laying in casement profile Route cable on / in casement - the cable must adapt to the pivoting range of the drive (lay with strap) - Cable must be protected against damage such as shearing off, kinking, cracking (e.g.
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Planning: Mounting bracket K87 for outward openning top-hung projecting window TD- Documentation Dimensions of window / Minimum Opening sequence of top-hung projecting window Planning table Mounting bracket K87 Prevention of common danger: Collision of chain with window profile min. Opening width Stroke ca.
Facing / Blinding of the drive TD- Documentation Blinding possibility for single application Variation 1 Variation 3 Variation 2 Blinding of drive Blinding variable Total blinding of drive (e.g. because of colour change) (e.g. total width of window) Brackets completely visible Brackets partially visible Brackets partially visible only covering profile...
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Facing / Blinding of the drive TD- Documentation covering profile drive Variation 1 Blinding of drive (e.g. because of colour change) Possible use in B-1 / B-2 K84-1 spacer covering profile drive Variation 2 Total blinding of drive Possible use in B-1 / B-2 K84-1 spacer...
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Facing / Blinding of the drive TD- Documentation Preparation for shortening profile Shortening the covering profile Determine profile length - select desired varation of drive - mark required length - cut off the remaining part with a saw blinding - Editing aid: slide - ensure that the cut is parallel (profile part of drive housing) - deburr end of profile as necessary...
Consideration of the safety and trial operation TD- Documentation Distortion of casement and breakage of window pane Activation element OPEN CLOSE Without synchronization of drives resp. white wires are not connected Check safety of assembled system Possible damages with improper assembly connect control voltage - check mounting (brackets, mounting brackets) and tighten as necessary Conduct trial run...
Electrical connection TD- Documentation Make appropriate connections, depending on the drive version. Note: The running direction of the drive can be changed by reversing (reversion of polarity) the „BN – (brown) “ - „BU – (blue)“ leads. 24V DC Version (KSA2) Version (KSA/KSA2) Version (for Tandem) Master...
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Electrical connection TD- Documentation Drive set identification (marking) ® KSA 400 MP Master ® KSA 400 MP Slave 1 ® KSA 400 MP Slave 2 s : 400mm s : 400mm s : 400mm U : 24V DC, 2 Vss U : 24V DC, 2 Vss U : 24V DC, 2 Vss +75°C...
Operating instructions Maintenance and care / cleaning TD- Documentation Activation of power-driven window Maintenance and care / cleaning The activation element of switches with a preset OFF- (e.g. To guarantee faultless operation, the following work has to be carried out after 1000 opening cycles and / or at least once a key switch) must be mounted in direct visual range of the driven part and at a safe distance from any moving parts.
Help in case of faults Disassembly and disposal TD- Documentation Disassembly and disposal Help in case of faults, repair and overhaul The procedure is the same as during assembly of the drives, however, in reverse order. The repair of a defect drive by a converter or end user Setup / adjustment work is omitted.
Mechanical and electrical safety TD- Documentation Mounting and fastening material Avoidance of dangerous situations Needed or supplied fastening material must be appro- Precautions must be taken prevent priate for structure and respective load and supple- the possibility of being trapped mented as necessary.
Warranty and servicing TD- Documentation Warranty and customer service Basically valid are „General Terms for goods and services of the Electrical Industry (ZVEI)“ The warranty is in accordance with national legal regula- tions of the country in which the drive was acquired. The warranty applies to material and manufacturing de- fects arising during normal operational demands.
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Notes TD- Documentation Mounting Instruction Chain drive KSA xxx-24 V / 230V Page 68 of 68 219-100-0-0-1.0.doc...
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TD- Documentation Mounting Instruction Chain drive KSA xxx-24 V / 230V 219-100-0-0-1.0.doc Page 69 of 68...
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