Kollias RSM, Technical Handbook

Page 1: ...0 INDUSTRIAL ROLLER SHUTTER RSM www kolliasdoors com TECHNICAL HANDBOOK ...

Page 2: ...tion of industrial roller shutter 5 Γ Technical specifications of transmission design system 11 Δ Installation manual 27 Ε User s manual 38 Ζ Maintenance manual 42 COMPANY S INFO COMPANY NAME KOLLIAS Ltd Location 3rd km National Highway Katerini Thessaloniki Sector Industrial Doors and Loading Bay Equipment Head offices address 3rd km N H Katerini Thessaloniki Zip Code 60100 Katerini P O Box 91 Te...

Page 3: ...rocessing department is fully equipped with state of the art CNC processing centers The design and implementation of electronics and electrical devices is processed by the testing laboratory which is the main factor for the complete production of mechanical electrical and electronic equipment by expanding the already large range of our products Kollias Ltd is investing in the logistics infrastruct...

Page 4: ...ling machines State of the art laser cutting unit with dual autonomy and power supply CNC strands with machining lengths of 8500mm and 4000mm Pulsate welding machines MIG MAG and welding machines TIG Machines producing single profile and double skinned profiles with PU insulation CNC composite robotic presses CNC cutter with machining length 4000mm and sheet cutting ability of 6mm Autonomous unit ...

Page 5: ...ge 5 46 D Z Ver 1st 08 12 17 Address 3rd km National Highway Katerini Thessaloniki Katerini Postal address P O Box 91 60100 Katerini Tel 30 23510 36036 Fax 30 23510 45630 Web www kolliasdoors com TECHNICAL DESCRIPTION OF INDUSTRIAL ROLLER SHUTTER WITH ANCHOR SYSTEM ...

Page 6: ...ying with the European Directive 305 2011 ΕΕ which are certified by a notified laboratory under European Standard EN 13241 1 Industrial roller shutters have adjustable operating speed and resistance to large wind pressures Figure 1 As it is shown in Figure 1 the winding device is mounted on the cantilever shaft which is supported by the vertical guides in turn of which rest on the building infrast...

Page 7: ...in is equipped with a single modular profile which enhances its robustness and stability The bottom bar has applied a high quality EPDM reinforced rubber to ensure sealing with the floor The rotation of the roller shutter s shaft around of which the curtain is wrapped is ensured by a three phase electric motor to which a suitable gear reducer is fitted The transmission assembly consists of the cha...

Page 8: ...anchor consists of a bifurcated plate in which two polyamide wheels are fitted The smooth rotation of the wheels is achieved by means of closed type bearing rings roller bearings and evolves into a suitably shaped cavity of the vertical guide Figure 4 In this way it is possible to anchor the curtain on the guides eliminating friction damages and noise The guide has longitudinal aluminum profiles o...

Page 9: ...l types of commercial motion detectors In addition it can be connected to a pair of industrial photocells optional equipment which are mounted in the vertical guides while it also has a built in remote control system with rolling codes and a stabilized frequency of information transfer special for industrial conditions The electronic control board has a digital communication port with our construc...

Page 10: ...epeaters or even a light signal may be placed on the product if requested Finally the structure can be equipped with a telescopic modular metal frame of wind protection where combined with the anchor system it offers much more resistance to the roller shutter against wind pressure The biggest advantage of the present product is the possibility of replacing or repairing all the mechanical and elect...

Page 11: ...d Page 11 46 D Z Ver 1st 08 12 17 Address 3rd km National Highway Katerini Thessaloniki Katerini Postal address P O Box 91 60100 Katerini Tel 30 23510 36036 Fax 30 23510 45630 Web www kolliasdoors com SPECIFICATIONS FOR MOTION SYSTEM OF INDUSTRIAL ROLLER SHUTTER ...

Page 12: ...0 37 Kw Speed n 2800 rpm Rated Torque Tm 1 3Nm Rated Voltage Vm 400 V Current Im 1 1A Frequency Fr 50 Hz Power Factor cosφ PF 0 75 Poles PL 2 Phases PN 3 Insulation MPf F Protection MPr ΙP55 Gearbox s Technical Specifications Type RTe MU 50 Transmission Ratio i 1 100 Torque ΤRE 48 Nm Gearbox Dynamic Efficiency RD 0 563 Service Factor SF 0 96 Min Operating Temperature WTi 25 o C Max Operating Tempe...

Page 13: ...en Zs 45 Sprocket Teeth Drive Zr 11 Shaft s Technical Specifications Diameter Ds 159 mm Thickness ts 3 mm End Shaft Diameter Drive Dm 30 mm End Shaft Diameter Driven DCB 30 mm Transmission s Technical Specifications Gearbox Governor Speed nr 28 rpm Barrel Speed ns 7 rpm Total Maximum Torque Τ 192 Νm Lifting Capacities Diameter Based G 240 Kg Final Drive iO 1 400 Duty Cycle W 90 Electronic Board s ...

Page 14: ... 55 Kw Speed n 2820 rpm Rated Torque Tm 2 0Nm Rated Voltage Vm 400 V Current Im 1 75A Frequency Fr 50 Hz Power Factor cosφ PF 0 80 Poles PL 2 Phases PN 3 Insulation MPf F Protection MPr ΙP55 Gearbox s Technical Specifications Type RTe MU 63 Transmission Ratio i 1 100 Torque ΤRE 110 Nm Gearbox Dynamic Efficiency RD 0 586 Service Factor SF 0 81 Min Operating Temperature WTi 25 o C Max Operating Temp...

Page 15: ...ven Zs 38 Sprocket Teeth Drive Zr 9 Shaft s Technical Specifications Diameter Ds 159 mm Thickness ts 3 mm End Shaft Diameter Drive Dm 40 mm End Shaft Diameter Driven DCB 40 mm Transmission s Technical Specifications Gearbox Governor Speed nr 28 rpm Barrel Speed ns 7 rpm Total Maximum Torque Τ 440 Νm Lifting Capacities Diameter Based G 550 Kg Final Drive iO 1 400 Duty Cycle W 90 Electronic Board s ...

Page 16: ...50 rpm Rated Torque Tm 5 1 Nm Rated Voltage Vm 400 V Current Im 4 7A Frequency Fr 50 Hz Power Factor cosφ PF 0 66 Poles PL 2 Phases PN 3 Insulation MPf F Protection MPr ΙP55 Friction Plate Electromagnetic Coupling System EM Brake Rated Voltage VBR 110 V Rated Power PBR 150 Watt Clutch Air Gap cl 0 5 0 7mm Axial Drive Force F 4500 N Instant Max Torque Brake TBR 30 Nm Gearbox s Technical Specificati...

Page 17: ...fications of Chaining Elements Chain Type CTe 12Β Pitch p 3 4 Sprocket Teeth Driven Zs 38 Sprocket Teeth Drive Zr 9 Shaft s Technical Specifications Diameter Thickness Φ1 159x3 mm Φ2 219x3 mm Φ3 273x4 mm End Shaft Diameter Drive Dm 40 50 mm End Shaft Diameter Driven DCB 40 50 mm Transmission s Technical Specifications Gearbox Governor Speed nr 28 rpm Barrel Speed ns 7 rpm Total Maximum Torque Τ 97...

Page 18: ...50 rpm Rated Torque Tm 5 1 Nm Rated Voltage Vm 400 V Current Im 4 7A Frequency Fr 50 Hz Power Factor cosφ PF 0 66 Poles PL 2 Phases PN 3 Insulation MPf F Protection MPr ΙP55 Friction Plate Electromagnetic Coupling System EM Brake Rated Voltage VBR 110 V Rated Power PBR 150 Watt Clutch Air Gap cl 0 5 0 7mm Axial Drive Force F 4500 N Instant Max Torque Brake TBR 30 Nm Gearbox s Technical Specificati...

Page 19: ...tions of Chaining Elements Chain Type CTe 20Β Pitch p 1 1 4 Sprocket Teeth Driven Zs 45 Sprocket Teeth Drive Zr 9 Shaft s Technical Specifications Diameter Thickness Φ1 219x3 mm Φ2 273x4 mm Φ3 324x5 mm End Shaft Diameter Drive Dm 50 60 mm End Shaft Diameter Driven DCB 50 60 mm Transmission s Technical Specifications Gearbox Governor Speed nr 28 rpm Barrel Speed ns 7 rpm Total Maximum Torque Τ 1765...

Page 20: ...50 rpm Rated Torque Tm 5 1 Nm Rated Voltage Vm 400 V Current Im 4 7A Frequency Fr 50 Hz Power Factor cosφ PF 0 66 Poles PL 2 Phases PN 3 Insulation MPf F Protection MPr ΙP55 Friction Plate Electromagnetic Coupling System EM Brake Rated Voltage VBR 110 V Rated Power PBR 150 Watt Clutch Air Gap cl 0 5 0 7mm Axial Drive Force F 4500 N Instant Max Torque Brake TBR 30 Nm Gearbox s Technical Specificati...

Page 21: ...tions of Chaining Elements Chain Type CTe 20Β Pitch p 1 1 4 Sprocket Teeth Driven Zs 54 Sprocket Teeth Drive Zr 9 Shaft s Technical Specifications Diameter Thickness Φ1 219x3 mm Φ2 273x4 mm Φ3 324x5 mm End Shaft Diameter Drive Dm 60 mm End Shaft Diameter Driven DCB 60 mm Transmission s Technical Specifications Gearbox Governor Speed nr 28 rpm Barrel Speed ns 7 rpm Total Maximum Torque Τ 2118 Νm Li...

Page 22: ...2860 rpm Rated Torque Tm 9 6Nm Rated Voltage Vm 400 V Current Im 8 7A Frequency Fr 50 Hz Power Factor cosφ PF 0 66 Poles PL 2 Phases PN 3 Insulation MPf F Protection MPr ΙP55 Friction Plate Electromagnetic Coupling System EM Brake Rated Voltage VBR 110 V Rated Power PBR 150 Watt Clutch Air Gap cl 0 5 0 7mm Axial Drive Force F 4500 N Instant Max Torque Brake TBR 30 Nm Gearbox s Technical Specificat...

Page 23: ...ions of Chaining Elements Chain Type CTe 20Β Pitch p 1 1 4 Sprocket Teeth Driven Zs 54 Sprocket Teeth Drive Zr 9 Shaft s Technical Specifications Diameter Thickness Φ1 219x3 mm Φ2 273x4 mm Φ3 324x5 mm End Shaft Diameter Drive Dm 60 70 mm End Shaft Diameter Driven DCB 60 mm Transmission s Technical Specifications Gearbox Governor Speed nr 28 rpm Barrel Speed ns 7 rpm Total Maximum Torque Τ 3312 Νm ...

Page 24: ...e 24 46 D Z Ver 1st 08 12 17 Address 3rd km National Highway Katerini Thessaloniki Katerini Postal address P O Box 91 60100 Katerini Tel 30 23510 36036 Fax 30 23510 45630 Web www kolliasdoors com INSTALLATION OPERATION MAINTANANCE MANUAL OF INDUSTRIAL ROLLER SHUTTER ...

Page 25: ...sary to secure the space around the place of installation of the roller shutter in order to avoid the passage of persons not related to the work The roll installation must be carried out by qualified personnel and in accordance with EN 12635 For the proper installation of the product the presence of at least two trained technicians is required on field For safety and convenience perform the instal...

Page 26: ...general and special safety regulations and accident prevention Knowledge of applicable electrical regulations Training in the use and maintenance of appropriate safety equipment Sufficient education and training by certified electrician installers Ability to recognize the risks that can be caused by electricity Ability to apply the following standards EN 12635 Industrial doors commercial and garag...

Page 27: ...IAS Ltd Page 27 46 D Z Ver 1st 08 12 17 Address 3rd km National Highway Katerini Thessaloniki Katerini Postal address P O Box 91 60100 Katerini Tel 30 23510 36036 Fax 30 23510 45630 Web www kolliasdoors com INSTALLATION MANUAL FOR INDUSTRIAL ROLLER SHUTTER ...

Page 28: ...escribe in detail the process of the installation of the Industrial Roller Shutters STEP 1 Basic checks before the installation of Industrial Roller Shutter Before starting any installation work make sure that the right space WR and left WL of the opening as well as the total height HT is sufficient to fit the guides this is not required when the installation is in tunnels meaning between the wall...

Page 29: ... there is a risk that the product may malfunction which may cause premature fatigue in its mechanical components STEP 2 Installation of Industrial Roller Shutter s Guides Since we have originally set the exact place of mounting of the guides lift one of the two seeking to be as vertical as possible By using control instruments spirit level or laser we adjust the position to ensure total verticalit...

Page 30: ...er STEP 3 Define the distance between vertical guides We lift the second guide and perform the corresponding actions with the first In order to safely define the distance between the guides it is suggested that the measurements be made between the inner surfaces of the shaped beams of the guide Figure 3 both in their upper and lower position Figure 3 As in the first guide special attention is requ...

Page 31: ...ther a crane or a forklift at a desired work height Then adjust the crank to the motor s socket and rotate it rotate the motor s mounting Figure 4 Corresponding rotation work is done for the base of the safety brake which can be accomplished easily by hand Figure 4 STEP 5 Positioning the roller shutter on the bearing and checking the gap between the shaft and the base Raise the roller shutter to a...

Page 32: ...HUTTER_ RSM KOLLIAS Ltd Page 32 46 D Z Ver 1st 08 12 17 Address 3rd km National Highway Katerini Thessaloniki Katerini Postal address P O Box 91 60100 Katerini Tel 30 23510 36036 Fax 30 23510 45630 Web www kolliasdoors com Figure 5 Figure 6 ...

Page 33: ...lly on the side of the motor s base for reasons of expediency Particular emphasis must be placed on the correct mounting support so that the gear chain is stretched thereby ensuring smooth operation on the roller shutter STEP 6 Adjust the roller shutter s curtain to the guides Having fixed the bases on the mountings we rotate the roller shutter using the crank so that the bottom bar can is settled...

Page 34: ... Figure 8 watching the BROWN wire being connected to the ASCEND button and the YELLOW cable with the DESCENT button Then we feed the board with three phase current and start the process of adjusting the terminals switches Figure 8 By pressing the DESCENT button we see in the terminal control board Figure 9 that the rotors move to the right In case that this does not occur we invert the two of the ...

Page 35: ...ROWN wire we notice that the rotors of the terminal board move to the left Raise the roller shutter to the position where the bottom bar and the roller shutters slat are located within the guides In this position we must adjust that the left rotor controlling the ascent presses the corresponding contact Then we lower the roller shutter and raise it to check that the previous terminal setting is ac...

Page 36: ...00 devices the electronic board is equipped with an asymmetry and phase sequencing control This device protects us from the wrong connection to the grid preventing the roller shutter from moving in the opposite direction causing problems in the terminal switches Note 4 To make sure that the wiring has been properly connected to the power grid the manual operation indication light should turn red e...

Page 37: ...6036 Fax 30 23510 45630 Web www kolliasdoors com Figure 10 1 Remove the four hexagonal head screws on the gear unit 2 Install the terminal system into contact and adapt it to the gear unit 3 Replace the hexagonal screws to hold the board in the gear unit Note 7 In order to properly operate and secure the roller shutter it is necessary that the floor with which the sealing rubber is in contact is f...

Page 38: ...d Page 38 46 D Z Ver 1st 08 12 17 Address 3rd km National Highway Katerini Thessaloniki Katerini Postal address P O Box 91 60100 Katerini Tel 30 23510 36036 Fax 30 23510 45630 Web www kolliasdoors com INSTRUCTIONS OF INDUSTRIAL ROLLER SHUTTER S PROPER OPERATION ...

Page 39: ... stops immediately by stopping any activity on it When the curtain reaches its upper or lower motion it stops automatically via the terminal switches even if we continue to operate with the button In case of circuit voltage drop every function of the industrial roll is immediately interrupted After resetting the voltage to the desired levels an effect is required on each roller control board as ea...

Page 40: ...ion During manual operation the terminals switches are set off Therefore special attention is needed in both cases when descending and ascending of the roller shutter Under no circumstances should they exceed the roller shutter s operating limits as they will cause damage to the terminal switches In order to operate manually the roller shutter you have to place and push the crank manual or by rota...

Page 41: ...atic mode we must rotate the pulley in the opposite direction from the original direction of rotation Be careful that the counterclockwise rotation of the chain should be mild the minimum applied force to activate the electronic circuit of the roller shutter ATTENTION To avoid any form of injury Proceed with ascending or descending of the roller shutter only when the opening is clear and free of a...

Page 42: ... Ltd Page 42 46 D Z Ver 1st 08 12 17 Address 3rd km National Highway Katerini Thessaloniki Katerini Postal address P O Box 91 60100 Katerini Tel 30 23510 36036 Fax 30 23510 45630 Web www kolliasdoors com MAINTENANCE INSTRUCTIONS FOR INDUSTRIAL ROLLER SHUTTER ...

Page 43: ... following tasks Checking the terminals switches for proper operation The boundary end positions of the curtain are determined by the terminal board Inspect visually if the terminal switches are correctly set by following the procedure below The roller shutter is properly adjusted and the curtain is normally down when the sealing rubber is tangled to the floor and the profiles keep the distance be...

Page 44: ... calculation According to DIN 8195 the type of lubrication is determined by the speed of the chain Lubrication must be done frequently the greater the chain speed and as much as the dust and moisture content is the operating environment of the product For the industrial roller shutters the speed does not exceed 0 2 m sec and therefore according to DIN 8195 the lubrication mode selected is manual l...

Page 45: ...t contains long lasting lubricant nevertheless check for leaks In case of leakage immediately contact an authorized repairer Also visually inspect the condition of the power cables of the electric motor If you find any damage contact an authorized repairer immediately Check the sealing and sliding profile of the curtain The guide carries along the aluminum profile of a suitable cross section the E...

Page 46: ...3510 45630 Web www kolliasdoors com ATTENTION Maintenance should be carried out more often if the door is subjected to a high level of use All faulty components must be replaced with genuine accessories Maintenance must be carried out by trained personnel These instructions must be observed when carrying out maintenance work It is important to follow the warnings and safety instructions Door maint...