FAAC 844, 780D, 844 ER Z16 CR, 844 R, 844 R CAT, 844 R RF Manual

OVERVIEW

These instructions apply to the following models:
844 ER Z16 CR - 844 R - 844 R CAT - 844 R RF

The FAAC mod. 844 automated system for sliding gates is an electro-mechanical operator transmitting motion to the sliding leaf via a rack or chain pinion appropriately coupled to the gate. The non-reversing system ensures the gate is mechanically locked when the motor is not operating and, therefore, no lock needs to be installed.

The gearmotor is equipped with a mechanical clutch which, combined with an electronic device, offers the necessary adjustable anti-crushing safety and guarantees stopping or reversing the gate movement. A handy manual release makes it possible to move the gate in the event of a power cut or malfunction. The control board, if supplied with the gearmotor, it is placed inside the operator.

The 844 automated system was designed and manufactured to control access of vehicles. Avoid any other use whatever.

Fig.1

1. Securing corners
2. Pinion
3. Limit sensor switch
4. Operator cover
5. 780 D Control board
6. Adjustment screw for anti-crushing clutch
7. Oil filling plug
8. Operator earthing
9. Lever operated release system
10. Protective side panels
11. Cover for 780D control board

The curve makes it possible to establish maximum work time (T) according to use frequency (F).

E.g.: The 844 gearmotor can operate non-stop at 70% use frequency.

To ensure efficient operation, operate in the work range below the curve.

The curve is obtained at a temperature of 24°C. Exposure to the direct sun rays can reduce use frequency down to 20%.

Calculation of use frequency
The percentage of effective work time (opening + closing) compared to total time of cycle (opening + closing + pause times).

Calculation formula:

where:
Ta = opening time
Tc = closing time
Tp = pause time
Ti = time of interval between two complete cycles

Use frequency graph

Tab. 1 TECHNICAL SPECIFICATIONS OF 844 GEARMOTOR

1. Operator 844 with 780D equipment
2. Photocells
3. Key-operated push-button
4. Flashing lamp
5. Radio receiver

INSTALLATION OF THE AUTOMATED SYSTEM

PRELIMINARY CHECKS

To ensure safety and an efficiently operating automated system, make sure the following conditions are observed:

• The gate structure must be suitable for automation. The following are necessary in particular: wheel diameter must be in proportion to the weight of the gate to be automated, an upper guide must be provided, plus mechanical stop limits to prevent the gate derailing.
• The soil must permit sufficient stability for the foundation plinth.
• There must be no pipes or electric cables in the plinth excavation area.
• If the gearmotor is exposed to passing vehicles, install, if possible, adequate means of protection against accidental impact.
• Check if an efficient earthing is available for connection to the gearmotor.

MASONRY FOR FOUNDATION PLATE

1. Assemble the foundation plate as shown in figure 4.
   
2. The foundation plate must be located as shown in figure 5 (right closing) or figure 6 (left closing) to ensure the rack and pinion mesh correctly.
   
3. Prepare a foundation plinth as shown in fig.7 and wall the foundation plate, supplying one or more sheaths for routing electric cables. Using a spirit level, check if the plate is perfectly level. Wait for the cement to set.
   
4. Lay the electric cables for connection to the accessories and power supply as shown in figure 3.

To make the connections efficiently, allow the cables to project by about 40 cm from the hole (Figs.5-6 ref. ) of the foundation plate.

MECHANICAL INSTALLATION

1. Assemble the securing corners and anti-vibration spacers on the operator as shown in Fig. 8.
   
2. Open the cover, unscrewing the securing screws.
3. Place the operator on the plate, using the supplied washers and nuts as shown in Fig. 9.
   
   During this operation, route the cables through the duct inside the lower half-casing of the operator (Fig.10 - Ref. A). To access the electronic equipment, route the cables through the appropriate hole, using the supplied rubber cable-clamp. Make absolutely sure to unsheathe all the cables so that the clamp holds single cables only (Fig.10 - Ref. B).
   
4. Secure the gearmotor to the foundation plate, tightening the nuts as in Fig.12.
   
5. Prepare the operator for manual operating mode as described in MANUAL OPERATION chapter.

1. Manually take the leaf into its closing position.
2. Lay the first piece of rack level on the pinion and place the spacer between the rack and the gate, positioning it at the top of the slot.
3. Mark the drilling point on the gate. Drill a Ø 6,5 mm hole and apply thread with a Ø 8 mm male tap. Screw the bolt.
4. Move the gate manually, checking if the rack is resting on the pinion, and repeat the operations at point 3.
5. Bring another rack element near to the previous one, using a piece of rack (as shown in figure 16) to synchronise the teeth of the two elements.
6. Move the gate manually and carry out the securing operations as for the first element, thus proceeding until the gate is fully covered.

Notes on rack installation

• Make sure that, during the gate travel, all the rack elements do not exit the pinion.
• Do not, on any account, weld the rack elements either to the spacers or to each other.
• When the rack has been installed, to ensure it meshes correctly with the pinion, we advise you to lower the gearmotor position by about 1.5 mm (Fig.17).
  
• Manually check if the gate habitually reaches the mechanical stop limits and make sure there is no friction during gate travel.
• Do not use grease or other lubricants between rack and pinion.

MOD. 844 ER RF (Figs. 20 - 21)

1. Insert the spring pin on the shaft, using a hammer.
2. Fit the idle transmissions bracket on the gearmotor flange, using the four screws (M5 x 12) and the appropriate washers, in the kit as shown in Fig. 20.
3. Fit the chain pinion on the shaft, making the pinion seats coincide with the spring pin and tighten the screw and the appropriate washers and.
4. Pass the chain as shown in Fig. 21 ref. A and install the housing with screw and washer as in Fig. 20.
5. In case of operators with MLS limit switches, arrange thesupports for the positioning of the magnets supplied while observing the dimensions given in fig. 21 ref. B.

CONTROL BOARD 780D

WARNINGS

Before attempting any work on the control board (connections, maintenance), always turn off power.

• Install, upstream of the system, a differential thermal breaker with adequate tripping threshold.
• Connect the earth cable to the terminal on J7 connector of the board, and to the bush on the operator (figs. 22 and 40).
• Always separate power cables from control and safety cables (push-button, receiver, photocells, etc.). To avoid any electric noise, use separate sheaths or a shielded cable (with earthed shield).

J7 Terminal board - Power supply

(fig. 23)

POWER SUPPLY (terminals PE-N-L):

PE: Earth connection

N: Power supply ( Neutral )

L: Power supply ( Line )

NB.: For correct operation, the board must be connected to the earth conductor in the system. Install an adequate differential thermal breaker upstream of the system.

FSW OP - Opening safety devices contact (terminal 3): The purpose of the opening safety devices is to protect the leaf movement area during opening. During opening, in the A-AP-S-E-EP logics the safety devices reverse the movement of the gate, or stop and restart the movement when it is released (see advanced programming in Chpt. ADVANCED PROGRAMMING). During the opening cycle in logicsthe B, C and B/C, they interrupt movement. They never operate during the closing cycle.

If the Opening safety devices are engaged when the gate is closed, they prevent the opening movement. To install several safety devices, connect the N.C. contacts in series (fig.25).

NB.: If no opening safety devices are connected, jumper connect inputs FSW OP and -TX FSW (fig. 26).

FSW CL - Closing safety devices contact (terminal 4): The purpose of the closing safety devices is to protect the gate movement area during closing. During closing, in the A-AP-S-E-EP logics, the safety devices reverse the movement of the gate, or stop and reverse the movement when it is released (see advanced programming in Chpt. ADVANCED PROGRAMMING). During the closing cycle in logics B, C and B/C, they interrupt movement. They never operate during the opening cycle. If the Closing safety devices are engaged when the gate is open, they prevent the closing movement. To install several safety devices, connect the N.C. contacts in series (fig.25).

NB.: If no closing safety devices are connected, jumper connect terminals FSW CL and -TX FSW (fig. 26).

STOP - STOP contact (terminal 5): any device (e.g. a pushbutton) which, by opening a contact, stops gate movement.
To install several STOP devices, connect the N.C. contacts in series (fig. 25).

NB.: If STOP devices are not connected, jumper connect the STOP and - terminals.

SAFE -EDGE safety device contact (terminal 6): The purpose of the "edge" safety device is to protect the leaf movement area during opening/closing. In all logics, during opening and closing, the safety device reverses gate movement for 2 seconds. If the safety devices operate again during the 2-seconds reversing time, it stops movement (STOP) without any reversing.
If the Edge safety device is engaged while the gate is closed or open, it prevents movement.
To install several safety devices, connect the N.C. contacts in series (fig.25).

NB.: If edge safety devices are not connected, jumper connect the SAFE and - inputs (fig. 26).

– Negative for power supply to accessories (terminals 7 and 8)
+ 24 Vdc - Positive for power supply to accessories (terminals 9 and 10)

Accessories max. load is 500 mA. To calculate absorption values, refer to the instructions for individual accessories.

J5 Connector -Rapid connection to Capacitor

Quick-fit connector for connecting the motor starting capacitor.

Double connector J8 - Limit-switch quick fit

Quick-fit connector for connecting the limit -switch. For connecting both the MLS limit-switch and the inductive limitswitch (fig. 23 ref. ) to the equipment.

PROGRAMMING

To program operation of the automated system, access the "PROGRAMMING" mode with keys F,+ and -, and using the display on the equipment.

Attention: before attempting to power up the system, we advise you to re-position the equipment's cover, to avoid coming into contact with high voltage parts, and to use the push-buttons on the cover to activate the keys (fig. 39).

Programming is divided in two parts: BASIC and ADVANCED.

BASIC PROGRAMMING

To access BASIC PROGRAMMING, press key F:

• if you press it (and hold it down), the display shows the name of the first function.
• if you release the key, the display shows the value of the function that can be modified with keys + and -.
• if you press F again (and hold it down), the display shows the name of the next function, etc.
• when you reach the last function, press F to exit the program, and the display resumes showing the gate status.

The following table shows the sequence of functions accessible in BASIC PROGRAMMING:

START-UP

ELECTRIC CONNECTIONS

Make all electrical connections to the board as in CONTROL BOARD 780D chapter, including earthing of the operator (Fig. 39).

DEFINITION OF OPENING DIRECTION AND OPERATION OF LIMIT-SWITCH LEDS

Power up the system and set the opening direction on the board (see par. BASIC PROGRAMMIN).

If opening direction is RIGHTWARD ( ):
OPENING limit-switch LED = FC1
CLOSING limit-switch LED = FC2

If opening direction is LEFTWARD ( ):
OPENING limit-switch LED = FC2
CLOSING limit-switch LED = FC1

DETERMINING THE STOP POINTS AT TRAVEL LIMIT

Operator 844 has a limit sensor switch which, by detecting the transit of a reference applied to the rack, commands the gate motor to stop. The device can be MLS (fig. 41) or inductive (fig. 42).

MLS limit-switch

The MLS limit sensor switch detects the transit of two magnets fitted on the side of the rack facing the operator.

Procedure for correct positioning of the two supplied magnets:

1. Check if the operator is in manual mode (see MANUAL OPERATION chapter).
2. Manually take the gate to opening position, leaving 2 - 5 cm from the travel limit mechanical stop.
3. Fit the magnet (without removing the protective film from the adhesive side) on the side of the rack facing the operator, aligning the upper edges. Slide the magnet on the rack in opening direction until the relevant LED goes off (Fig. 22 and 41), then move the magnet forward a further 45 mm.
4. Manually take the gate to closing position, leaving 2 - 5 cm from the travel limit mechanical stop.
5. Fit the magnet (without removing the protective film from the adhesive side) on the side of the rack facing the operator, aligning the upper edges. Slide the magnet on the rack in closing direction until the relevant LED goes off (Fig. 22 and 41), then move the magnet forward by about a further 45 mm.
6. Take the gate to its halfway travel point and relock the system (see ESTORING NORMAL OPERATIO chapter).
7. Find out the desired pre- and post-limit-switch deceleration values (see parag. ADVANCED PROGRAMMING) and run the automated system for at least one complete cycle.
8. Check if the gate stops at about 2 - 5 cm from its mechanical stop point. If necessary, correct the position of the magnets and check if the stop point is correct.
9. Mark the position of the magnets on the rack, and remove them.
10. Clean the rack on its fitting points, remove the film on the adhesive parts of the magnets (fig. 41 ref. 1) and reposition the magnets with the adhesive strip in contact with the rack (fig. 41 ref. 2).

Attention: due to the powerful magnetic fields the supplied magnets produce, the magnets can damage magnetic band components (credit cards, magnetic tapes, floppy disks, etc) and electronic and mechanical equipment (e.g. watches, LCD screens). We advise you not to bring them near to objects that could be damaged if 'immersed' in a magnetic field.

Notes on magnet positioning

• To ensure correct operation, allow at least 2 cm from the mechanical stop limit in the gate stop position. Carry out this check after determining the values of the pre- and post-limit switch decelerations (see par. ADVANCED PROGRAMMING) and after running at least one complete cycle of the automated system.
• The distance between the limit-switch and magnets must befrom 5 to 12 mm.
• Magnets should be fitted on the rack and not on the fixing screws. If necessary, position the magnet at the side of the screw and adjust decelerations (parag. ADVANCED PROGRAMMING) in order to obtain the correct stop point

Inductive limit-switch

Operator 844 has an inductive limit-switch which detects the transit of the two steel plates fitted on the top of the rack. Procedure for correct positioning of the two supplied steel plates:

1. Assemble the limit-switch by centring the plate with respect to threaded pins of the support (Fig. 42).
2. Check if the operator is in manual operating mode (see MANUAL OPERATION chapter).
3. Manually move the gate to opening position, allowing 2 - 5 cm from the mechanical stop limit.
4. Allow the plate to move on the rack in opening direction until the relevant LED goes OFF (Figs. 22 and 42); next, move the plate forward by about another 45 mm and secure it to the rack by tightening the screws.
5. Manually move the gate to closing position, allowing 2 - 5 cm from the mechanical stop limit.
6. Allow the plate to move on the rack in closing direction until the relevant LED goes OFF (Figs. 22 and 42); next, move the plate forward by about another 45 mm and secure it to the rack by tightening the screws

Notes on plate positioning

• To ensure correct operation, allow at least 2 cm from the mechanical stop limit in the gate stop position. Carry out this check after determining the values of the pre- and post-limit switch decelerations (see par. ADVANCED PROGRAMMING ) and after running at least one complete cycle of the automated system.
• The distance between the limit-switch and the plates must be< 5mm.

CHECK OF INPUTS

The table below shows the status of the LEDs in relation to to the status of the inputs.

Note the following:
LED LIGHTED = closed contact
LED OFF = open contact

Check the status of the LEDs as per Table.

Tab. 2 Operation of the signalling status LEDs

NB.: The status of the LEDs while the gate is closed at rest are shown in bold. If opening direction is leftward, the status of LEDS FC1 and FC2 is reversed.

CHECK OF MOTOR CONNECTION

Check if the motor wiring is as shown in F i g. 43 (standard connection).

ADJUSTMENT OF MECHANICAL CLUTCH

In addition to its electronic safety devices (encoder and force adjustment), the 844 operator is also equipped with a mechanical clutch.

For gate force and the encoder, please consult paragraphs BASIC PROGRAMMING and ADVANCED PROGRAMMING

Procedure for adjusting the operating threshold of the mechanical clutch (you are recommend to set it to conform with current regulations):

1. Cut electrical power to the automated system.
2. Keep the motor shaft locked with a wrench and turn the clutch adjustment screw with an Allen wrench or screwdriver as shown in Fig. 44 Ref 44.
   
   To increase torque, turn the screw clockwise. To reduce torque, turn the screw anti-clockwise. The operator is supplied with the clutch set to maximum level. Therefore, you must initially turn the screw anticlockwise to reach the best setting.
3. Power up the automated system and check that the torque you have just set is correct.

The operator is supplied as standard with a clutch adjustment spring for gates up to 1000 kg. For heavier gates, use the supplied alternative spring. For spring replacement instructions, see Fig. 44 Ref. B.

CHECK OF STOP POINTS

Take care over the setting of the post-limit-switch deceleration and braking: If deceleration is too long and braking is insufficient, the reference fitted on the gate's rack (magnet or steel plate) can overtake the sensor until the latter is disengaged. When the gate stops, check if only the limit-switch involved is engaged. The relevant LED must be OFF - if it went OFF and then ON again, or if both the limit-switch LEDS are OFF, you must reduce the post-limitswitch deceleration value and/or increase braking value (see par. ADVANCED PROGRAMMING).

SAFETY DEVICES AND ACCESSORIES CHECK

Check correct operation of all the safety and anti-crushing devices (ENCODER sensor), and of the accessories used on the system.

Remove the vent stop screw (fig. 47).

Hand the "User's Guide" to the Customer, explain correct operation and use of the gearmotor, and indicate the potentially dangerous areas of the automated system.

1. Open the protection door and fit the supplied key in the lock (Fig. 48).
   
2. Turn the key clockwise and pull the release lever as shown in Fig. 49.
   
3. Open and close the gate manually.

To prevent an involuntary pulse from activating the gate during the manoeuvre, cut power to the system before re-locking the operator.

1. Re-close the release lever.
2. Turn the key anti-clockwise
3. Remove the key and close the lock protection door.
4. Move the gate until the release meshes.

INSTALLING THE CN 60E CONTROL UNIT (OPTIONAL)

The operator is designed to house (with the aid of a DIN bar) the CN 60E control unit of the safety conductive edge. Cut the DIN bar to measure and secure it to the operator with two screws in the appropriate holes and attach the CN 60E control unit to it (Fig. 50).

For connection and operation, refer to the specific instructions.

INSTALLING REMOTE BOARD 578D

If you prefer to install the control board separately from the operator, you must use remote board 578D. In this case, an interface card is fitted on board the operator (fig. 51). For connections from the interface card to the remote board, please refer to the specific instructions on the 578D board.

If you wish to install the 462DF control board on the operator, you must use the appropriate adapter kit (Fig. 52). To install it, refer to the specific instructions.

SPECIAL APPLICATIONS

There are no special applications.

Check the operational efficiency of the system at least once every 6 months, especially as regards the efficiency of the safety and release devices (including operator thrust force).

DISASSEMBLING THE TRANSFORMER-BOARD UNIT

If you have to disassemble the transformer-board unit, proceed as follows:

Remove all terminal boards and connectors from the board. Unscrew the 3 securing screws of the board and the 2 of the transformer. Lift the unit up and gently remove the transformer from the couplings on the board as shown in Fig. 53.

OIL TOP-UPS

Periodically check oil level inside the operator.

A once-a-year check is enough for medium or low use frequency. For heavier duty, every 6 months is recommended. To access the tank, temporarily remove the oil filling plug (Fig. 54).

Oil level (visually checked) must be in line with the copper windings of the electric motor.

To top up, pour in oil up to the required level. Use FAAC XD 220 oil only.

REPAIRS

For any repairs, contact the FAAC authorised Repair Centres.

Read the instructions carefully before using the product and keep them for future consultation.

GENERAL SAFETY REGULATIONS

If installed and used correctly, the 844 automated system will ensure a high degree of safety.

Some simple rules regarding behaviour will avoid any accidental trouble:

• Do not stand near the automated system and do not allow children and other people or things to stand there, especially while it is operating.
• Keep radiocontrols or any other pulse generator well away from children to prevent the automated system from being activated involuntarily.
• Do not allow children to play with the automated system.
• Do not willingly obstruct gate movement.
• Prevent any branches or shrubs from interfering with gate movement.
• Keep illuminated signalling systems efficient and clearly visible.
• Do not attempt to activate the gate by hand unless you have released it.
• In the event of malfunctions, release the gate to allow access and wait for qualified technical personnel to do the necessary work.
• After enabling manual operating mode, switch off the power supply to the system before restoring normal operating mode.
• Do not make any alterations to the components of the automated system.
• Do not attempt any kind of repair of direct action whatsoever and contact FAAC qualified personnel only.
• Call in qualified personnel at least every 6 months to check the efficiency of the automated system, safety devices and earth connection.

DESCRIPTION

The 844 automated system is ideal for controlling vehicle access areas of medium transit frequency.

The 844 automated system for sliding gates is an electromechanical operator transmitting motion to the sliding gate via a rack or chain pinion appropriately coupled to the gate. Operation of the sliding gate is controlled by an electronic control equipment housed inside the operator.

When, with the gate closed, the equipment receives an opening command by radiocontrol or from another suitable device, it activates the motor until the opening position is reached.

If automatic operating mode was set, the gate re-closes automatically after the selected pause time has elapsed. If the semi-automatic mode was set, a second pulse must be sent to close the door again.

An opening pulse during re-closing, always causes movement to be reversed.

A stop pulse (if supplied) always stops movement. For details on sliding gate behaviour in different function logics, consult the installation technician.

The automated systems include accessories and safety devices (photocells, edges) that prevent the gate from closing when there is an obstacle in the area they protect. The system ensures mechanical locking when the motor is not operating and, therefore, no lock needs to be installed. Manual opening is, therefore, only possible by using the release system.

The gearmotor is equipped with an adjustable mechanical clutch which, combined with an electronic device, offers the necessary anti-crushing safety, by guaranteeing reversal of closing motion or stopping of opening motion. A sensor detects transit of the references fitted on the rack, which correspond to the travel limit positions. The electronic control equipment is housed in the gearmotor. A handy manual release makes it possible to move the gate in the event of a power cut or malfunction.

The warning-light indicates that the gate is currently moving.

MANUAL OPERATION

If the gate has to be operated manually due to a power cut or malfunction of the automated system, use the release device as follows:

1. Open the protection door and fit the supplied key in the lock as shown in Fig. 1.
   
2. Turn the key clockwise and pull the release lever as shown in Fig. 2.
   
3. Open and close the gate manually.

RESTORING NORMAL OPERATION

To prevent an involuntary pulse from activating the gate during the manoeuvre, cut power to the system before relocking the operator.

1. Re-close the release lever.
2. Turn the key anti-clockwise
3. Remove the key and close the lock protection door.
4. Move the gate until the release meshes.