一、Installation
（一）、Installation Materials List
1、Materials List
- Structural materials: lower lintel chord, lower lintel, curtain fixing frame, lateral guide rail, sealing system, curtain, rubber sealing strip
- Auxiliary materials: high-strength stainless steel bolts, anti-rust paint, lubricating grease, rubber sealant
2、Key Equipment List
- Driving and transmission equipment: reduction motor, wire rope drum, movable pulley block
- Control and safety equipment: PLC frequency conversion control cabinet, non-contact limit sensor, sound and light alarm, safety insurance mechanism
3、Consumable parts and consumables: wire rope, reducer gear oil, limit switch
（二）、Confirmation of Equipment Installation Conditions
- Building and structural requirements: The door opening installation dimensions of the building should meet the requirements of the drawings, with an error of ±10mm;
- Steel structure and power supply requirements: After the gate distribution beam is installed, welding is carried out, rust removal is carried out on the surface of the steel structure, and the structural load and structural roof subsidence are tested to meet the design requirements;
- Installation tools and safety measures: The three-phase four-wire power supply must be pulled to the gate control box, the power supply is 380V, and the temporary power connection point during construction shall not exceed 100m;
- Installation tools: laser theodolite, torque wrench, hoist, level;
- Safety measures: neatly stack various materials at the construction site, and organize the erection, installation and commissioning of construction machinery and facilities;
- Check whether the building structure meets the construction requirements, check the width, height and thickness of the door opening; check the verticality of the guide rail installation surface
（三）、Installation Process and Steps
- Positioning and measurement: Position and measure the door opening, check the door opening dimensions, and check the verticality of the guide rail installation surface;
- Install the guide rails and guards according to the construction drawings;
- During the installation of the drive system, he is mainly responsible for the hoisting and positioning of the hoist, and the commissioning of the wire rope drum;
- The installation of movable columns mainly involves the lifting and adjustment of columns and the fixing and sealing of bolts;
- When installing the lower lintel, you need to pay attention to using the safety clamp for debugging;
- Curtain fixing frame and door curtain assembly;
- Sealing system installation, focus on checking whether the sealing strip is installed tightly;
- Electrical wiring and control box installation;
（四）Debugging and Trial Operation
- Limit switch test (upper and lower limits)
- Motor and transmission system debugging
- Overall operation test (slow start and slow stop function)
（五）Installation Notes
- Wire rope protection and welding anti-rust
- Wire rope protection and welding anti-rust
二、Repair and Maintenance Guide
（一）Daily maintenance
- Wire rope inspection (monthly)
- Lubrication and maintenance (transmission parts, wire ropes)
- Limit switch cleaning and function testing
（二）Regular maintenance cycle
- Quarterly maintenance (3 months)
Wire Rope Wear Detection and Replacement Standards
Inspection of guide wheel of cord fixing frame
- Annual maintenance (12 months)
Reducer lubricating oil replacement
Overall structural strength inspection
（三）Common Troubleshooting
- Electrical Failure
- The indicator light is off -> Replace the indicator light/check whether the external power supply is input
- Mechanical failure
- Door stuck -> Check mechanical part, thermal relay reset
- The door does not rise horizontally -> the wire rope falls off, adjust the length of the wire rope
- Safety system failure
- Limit failure -> Check the limit device
（四）Safety operating regulations
- Prohibited Conduct
- Stay below when ascending or descending
- Press the switch at the same time
- Emergency treatment
- Wire rope breakage
- Motor overheating
三、Appendix
-
Electrical Schematics
The electrical schematics are provided by the manufacturer or professional engineers. Contact us to obtain detailed drawings.
-
Wearing parts replacement list
|
Part Name |
Replacement cycle |
Replacement Standard |
| Wire Rope | Check every 3 months and replace if necessary | The wires shall be scrapped when the broken wires exceed 10% of the total wires, the wires are severely corroded or the diameter is reduced by 7%. |
| Reducer lubricating oil | 24 months | Replace the oil when it is turbid or the viscosity does not meet the requirements. |
| Limit switches | 3 months cleaning, replacement when faulty | Replace the contact if it is oxidized, blocked or malfunctions. |
| EPDM sealing strip | 12 months | Replace when aging, cracking or losing elasticity |
| Electric bolt | 6-month inspection, replacement in case of failure | Replace when the latch is stuck or the electric mechanism fails |
| Wire Rope Clamp | Check every 3 months and replace if loose | Tighten/replace the clamp bolt if it is under-torqued or has stripped threads |
- Installation Tools and Materials List
Tool List：
| Tool Name | Specifications / Application | quantity |
| Hoist | 5 tons for lifting columns and lintels | 2 units |
| Electric welding machine | AC welding machine for steel structure welding | 1 units |
| Theodolite / Level | Measuring rail verticality and flatness | 1 each |
| Torque wrench | Calibrating the tightening force of high-strength bolts | A handful |
| Cutting Machine | Cutting rails and profiles | 1 units |
| multimeter | Detect circuit continuity and voltage | 1 block |
| Level | Adjust the levelness of the lower lintel | 1 |
Note：
- When replacing wearing parts, strictly follow the “Daily Care and Maintenance” clauses to ensure safety.。
- The quantity of installation tools and materials needs to be adjusted according to the actual door opening size and site conditions.
