ISO SPEED COLD

OPERATING INSTRUCTIONS

„ISO SPEED COLD“

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ISO SPEED COLD

Technical documentation and assembly instructions

High-Speed Sectional Door

For Deep-Freeze Areas

ISO SPEED COLD

Read the following instructions carefully prior to installing the door.

Contents:

1. Mechanical assembly instructions

1.1 Check space required

1.2 Preparation of the side frames
1.3 Setting up the side frames
1.4 Motor and bearing brackets
1.5 Fixing the shaft for belt
1.6 Assembly of the motor
1.7 Installation of the control box
1.8 Connection motor / control
1.9 Assembly of the roller rail
1.10 Assembly of the door panels
1.11 Greasing the roller rails
1.12 Functional test

2. Maintenance
3. Drawing vertical lift; deflector door

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ISO SPEED COLD

1. Mechanical assembly instructions

High-Speed Sectional Door

The door is delivered on 3 one-way pallets.

The delivery consists of: 1 pallet with 2 side frames and heavy-duty retaining strap
1 pallet with roller rail and suspended support
1 pallet with the door panels
1 motor with the control cabinet
Small parts and fittings in a box on the pallet together with the
side frame

1. Check space required

Check the clear space available for installation and the space required for the
side frames, the shaft for the heavy-duty retaining strap and the motor.
Measure the length of the side frames and compare them to the height of the room.
Check the amount of space required for the lintel.

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Check whether the wall and the ceiling to which the door will be attached can take

up the additional load of the door.

Check the floor for any unevenness or sloping – the left and right side frames must
be 100% perpendicular under all circumstances, since otherwise the door panels
will be unevenly deflected.
A difference in the floor level of more than 5 mm from left to right must be levelled
out by lining the side frames or, if necessary, by a slightly uneven displacement of
the roller rail arc.

2. Removal of the transport packaging and preparation of the side frames

The side frames are attached to the pallets with screws for transport.
Unscrew and remove these screws (M12). Undo the M6 hexagonal cap screws to
remove the covering panels from the side frames.
Mark the covering panels to ensure exact repositioning later on.
Take great care when handling the side frames, as the counterweights may weigh
up to 300 kg per side.
There is a serious risk of injury if the side frame topples over unexpectedly. The
counterweight is equipped with a safety device for transport that is to be removed
only after the side frames have been set upright. The counterweight must be
positioned at the sole plate when setting the side frames upright, if necessary, move
it there first.

3. Setting up the side frames

Note the amount of space required to swivel the frames.

Take into account any existing pipes, lights, or ventilation fittings, etc.
Take care not to damage the floor!
Use an appropriate lifting device to set up the side frames, such as a fork lift,
crane or chain hoist.

Do not place people or material at risk!

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Each side frame must immediately be secured by means of screw clamps or

tightening straps to prevent turning over.
Ensure that both side frames are completely straight in all directions.
Mount the spacer tubes included in the door package to help in maintaining the
required dimensions. Check inside the width of the door at the top side, at the
bottom and in the middle. Realign if necessary.

Check again whether the side frames are 100% perpendicular at the bottom.
A spirit level or other levelling instrument must be used.
Attach the side frames at the top and at the bottom. If the part of the wall used to
attach the frames is not even, it might prove necessary to attach the side frames to
the wall at additional points. Do not install any fixing devices near the area in which
the counterweights move, since the weights could get caught on them. These
additional points of attachment are marked in the drawing (p. 3).

4. Attaching the brackets on the side of the motor or the bearings

Check whether the fastening screws or the threaded rods of the wall fastening
protrude in such a way that the clamping plate of the bearing bracket could push
against or move it. In that case first move the plate, then push in the support and
tighten up the screws.

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5. Fixing the shaft for the heavy-duty retaining strap

Check all parts are complete and ensure that the bearings or set collars can be
moved before fixing the shaft for the heavy-duty retaining strap.

Note: Place the screw type bearings in the bearings while the piece is still on
the ground (M12 screw, washer, spring washer and nut).
Put the drum for the strap for the counterweight on the journal of the
shaft with the collar and locking screw pointing to the outside.

Note: Check the direction of winding of the strap

The heavy-duty retaining strap runs at the front.

The straps for the panels run at the back.

DOOR DOWN – weight up

DOOR UP – weight at the bottom
Move the shaft for the heavy-duty retaining strap in the
bearing brackets only so far in the direction of the wall
that the bridges of the strap do not touch.

Check the horizontal position of the shaft after it has been fixed and that it can
rotate freely
if necessary, loosen the clamping joint C-profile / bearing support on
one side and raise the bearing support (The upper edge of the C-profile equals the
upper edge of the bearing support).
The bearing support can only be lowered by a very small amount, since
otherwise the panels of the door could push against the bridges of the
straps of the panels.

The door panels would be damaged the first time the door runs!

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Note: Tighten the upper screw type bearing first, then the lower as this
results in a slight rising of the bearing and thus the flat head bolt
cannot break through the bearing housing.

6. Preparation and placing of the motor

Note: Take care that the revolving hollow shaft in the gear does not rub
against the vibration damper on one side or gets jammed.

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Should it prove necessary to change the motor side, e.g., if a door built for the
motor on the left needs to be assembled with the motor on the right, the winding
direction of all 6 straps must be changed over.
The drum for the heavy-duty retaining strap is to be placed accordingly.
The straps of the panels are to be unwound completely, the attachment screw is to
be removed, turned 180° and attached again. Then wind the straps again up. The
gusset on the centring angle of the shaft (pos. 3) must be removed. In some cases
the connecting cables for the heating elements of TK-models (freezer models) could
be too short and the cables must be lengthened professionally.

7. Installation of the control cabinet

The upper edge of the control cabinet should not be higher than 2 m above the floor.
The emergency stop switch must always be placed within easy reach.
Ambient conditions such as temperature, humidity, and easy access are to be taken
into account.
The working voltage is 400 volts.

Special features TK (freezer):

Cf. Appendix to the electrical documentation at the end of this manual.

8. Connecting the motor to the control cabinet

Before initial operation of the electric drive unit, it is necessary to ensure that the
door is securely attached and the motor, the vibration damper and the screw type
bearings of the shaft for the heavy-duty retaining strap must be fully tightened up.
Ensure that the straps run freely in the guides, there should be no ladders leaning
against the door, and no tools should be lying close to, on or in the door.
Remove the emergency crank handle.
Switch on the power, set the motor parameters and carry out the first running test.
(The electric supply and programming should be carried out in accordance with the
HÖRMANN training course.)
Align the shafts. The locking screws of the bearing, set collars and the drum for the
heavy-duty retaining strap are to be fastened. Note that the drum for the straps
should be moved as far as possible towards the bearing.

9. Assembly of the roller rail and suspended support

(cf. additional page to the technical drawing [susp. support])

First fit the M8 screw (Pos.229), which is to be screwed through the angle bracket
welded onto the side.

Lift or lower the roller rail so far that all other drilled holes align perfectly and the flat
head bolts (pos. 233) can be installed easily.
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Use the holding straps to hang up the roller rail provisionally, then fit the second
roller rail accordingly and mount at the final installation angle (pos. 220).

Measure the distance of the roller rails from the side frames. Make sure that the
distance is the same on each side by shifting in the oblong holes at the end of the
closing element. Now tighten the screw (pos. 236).

Check whether the assembly angle (pos. 220) hangs horizontally.

Check whether the arc elements (pos. 204+214) are free of stress and strains and
not misshapen.
The configuration of the suspended support depends upon the local situation and
the size and weight of the door (at least 2 suspended supports are to be mounted
per side – cf. technical drawing „Abhängung“).
As it might be necessary to remove the arc elements, special attention should be
paid to the fact that the framing consisting of the side frames and the door shaft as
well as the roller rails with the suspended support should be a supporting
construction of its own.

The correct slope of

the roller rails of the
suspended support must be
observed. It is 3°.
This corresponds to
Example:
Slope of susp. Support 5.5 cm per meter.
= 19,2 cm as allowed

10. Assembling the door panels

1. Fasten the heavy-duty retaining straps to the counterweights.

Pull up the counterweights one after the other by means of the motor (min. 1.5m)
and secure them against dropping with the help of the safety device for transport
that has been removed before. After both counterweights have been pulled up, you
have free access to the fastening screws of the lower roller rail element (pos.
8.5+9.5).
Remove the screws (M6) and the rails on both sides.
The panel rolls and springs can now be prepared (pos. 24+27).

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Note: The bolts (2 pcs) of the bottom section (pos. 25) are about
15 mm longer than the bolts of the other sections.

The panels are numbered. The bottom section is numbered No. 1; all subsequent
sections are marked with 2, 3, 4 etc.
The top section has a seal on the side of the wall (pos. 17) and on the side of the
heating element at the lintel (pos. 59).
Now, one panel strap is clamped only for assembly purposes left and right to the top
element and under the upper terminating fixing (pos. 28).

Doors with a width / height of 3.00 x 3.00 m can be pulled up without making use of
the counterweights. In the case of larger doors a counterweight needs to be hung
up and the weight must then be pulled up. The maximum travel must be observed.

The panel strap must be completely unwound. The diameter of the panel straps
must be identical on both sides, since otherwise the door leaf would skew between
the roller rails and jam immediately.

Insert the rollers (short bolts) with the springs on left and right sides in the top panel
and connect them to the holding straps at a height of approx. 1.40m.
Insert the bolts slightly greased. Do not use any force, since otherwise the sleeves
or hinges could be damaged.

Bring the control system in “emergency drive” mode (par. 980) and raise the door by
means of the “door up”  button until the rollers run in the roller rail.
Check whether the panel hangs horizontally in the straps (use a spirit level for
proper alignment). The more precisely this is done; the easier it is to insert the other
panels. When raising the panels, take great care not to damage the plastic coating
at the open end of the roller rail when the rollers run into it.
Now take the panel with the next lower number and connect it to the panel that is
already suspended by inserting the special steel sleeve (pos. 26.4) and the roller
with spring. Install the locking screw of the slip sleeve M5x5 (pos. 83) immediately
and apply a drop of appropriate Loctite. If available, also insert and secure the bolts
of the connecting hinges in the panel surfaces (middle hinges). Attach all other
panels as described before. Use the 2 longer bolts (pos. 24) for the bottom section,
as described above.

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Now mount the connection angle of the energy chain and make the electrical
connection to the electronic contact strip and, if necessary, the panel heating
element.

Assemble the pieces of the roller rails that were removed when the bottom section
is mounted and hangs slightly above the floor. Pull the panels slightly into the room
for that purpose and push the rail (left and right at the same time) from the bottom
onto the rollers. Push the panels back straight up and fit all screws which are
accessible. If any of the drilling holes should be blocked at this stage by the
counterweight, make sure that these screws are tightened as soon as the weight as
been pulled up.

Now take 2 blocks of the same height (approx. 10 cm – use the door pallet if need
be) and put them under the bottom section. Place the panels onto the blocks. Lower
the door until the panel straps are free of load. Loosen the clamping joints at the top
panel. Pull up the counterweight used to facilitate the hanging up of the panels to a
maximum and the panel straps are to be wound up or down so that there just one
winding covering the locking screw, for safety purposes. (Use the same procedure
on both sides).
Now slide the tensioning straps down to the bottom and pull them under the bottom
panel and through the strap deflector fitting (pos. 23) up again.

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Lower strap deflection

Do not twist the straps. Insert the straps in the lower

clamp and tighten the screws. Ensure that the straps are
tensioned evenly. Attach the protruding ends of the straps
in such a way that they cannot get stuck anywhere.

Check whether the door panels are horizontal and

whether the space between the door panels and the roller
rails is identical on both sides (if necessary, align by
lowering one side or by loosening the clamp of the strap). Lower the panels down to
the bottom.

2. Hanging up the counterweights and securing the strap ends

Check that the space for the travel of the

counterweights and the door panels is free
of all obstacles. Carry out a test run and
set the end positions. Then install the
separate plastic heating frame consisting
of 2 vertical elements (pos. 57+58) and the
lintel element (pos. 59). Mount the vertical
elements first and then check the correct
end position again. Push the horizontal
element at the side of the wall up until the
green corner elements push into the
horizontal rubber element. Lead the cable
of the heating element bearing side
through the free cable duct on the heating
element at the lintel.

Thoroughly grease the guide of the spring limit stop and move it until an initial
tension of approx. 100mm is obtained.
This results in a slight slip when the door closes.

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Note: There is a serious risk of injury whenever the door moves as long as
the covering panels of the side frames have not been mounted, due to
the moving counterweights.
Take great care when handling the door.
Keep eye contact with the door at any times and use the HÖRMANN
cable remote control if there is any doubt.

Check the position of the counterweights and realign them if necessary. The
counterweights should just touch the floor when the door panels are at the upper
end position. Should this not be the case, loosen the clamping joint at the
counterweight and adjust the length of the strap (do not cut off the strap).
Secure the ends of the straps as before with the panel straps.

Mount the security devices and connect them. The

correct positioning of the light barrier(s) behind the
covering panel must be observed.

Reinstall the covering panels as marked before.

11. Greasing the roller rails

The roller rail has to be greased on its entire length.

Note: Deep-freeze grease is to be used with doors used in deep-freeze areas.

12. Functional test

All functions of the door and all safety devices must be checked on proper
functioning. All parameters of the frequency converter entered must comply with the
standards of the door. Input voltage and motor current must be measured and are
to be noted in the certificate of delivery. Please also note the a missing of the final
supply line in the certificate.

Fill in the test booklet, sign it and affix the first inspection label to the type plate.

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2. Maintenance

The following maintenance work should be carried out at least every six months by a trained
technician. A trained technician is someone who is familiar with the mechanical and electrical
operational functions of the door system mentioned above.

Maintenance does not extend the guarantee period.

1. Examination of all mechanical mounting points by which the door is attached to the building
or the frame
2. Examination of all load-bearing components for cracked or broken parts or any other
damage
3. Examination of the vibration damper of the drive unit with regard to mechanical solidity
4. Examination of the stop position switch for functioning and switching-off position
5. Examination of the safety features such as the contact strip (if installed) and light barriers
for trouble-free functioning

Have the following maintenance work carried out at least every 12 months by a trained technician:

1. Examination of all screwed connections of the door systems

2. Examination of the flanged end devices for smooth running and of the mechanical
connection between the locking screws and the journal shaft
3. Examination of the set collars adjacent to the flanged end devices for correct positioning
and the mechanical connection between their locking screws and the journal shaft
4. Examination of the door panels for any damage, for smooth running in the roller rail
5. Examination of the emergency devices of the drive unit (emergency stop switch and
emergency crank limit switch) for trouble-free functioning
6. Examination of the setting of the PKZ-M motor protection switch. Make sure the switch
is adjusted to the current consumption nominal value
7. Examination of the actuation unit for loss of oil and unusual noise

Provide evidence of all maintenance work performed and keep it with your test documents.

Attach a test sticker to the door stating the date of the last/next maintenance service.

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Drawing vertical lift

5

29

29

9
10 8

14
28
24
10
23

13 6a /b/c
1

18b
12
17

27

12

18a
12
20
25
19

11
22 26
21
30

7a /b/c 16
15

21
26

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Drawing deflector door

5

29

34
3 31

10

14 28
29
24
23
32
2
35 13
8
9

10 18b
12
33
17

27

12

18a
12
20
25 19
6a /b/c

22
11
26
1 21
30

7a /b/c 16
15

21
26

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