MOTOPPAR INDÚSTRIA E COMÉRCIO DE AUTOMATIZADORES LTDA.Av. Dr. Labieno da Costa Machado, 3526 - Distrito Industrial - CEP 17400-000 - Garça - SP - Brasil

www.ppa.com.br+55 (14) 3407-1000

callcenter@ppa.com.br

WARNING:Do not use the product without fi rst reading the instruction manual.

Technical manual

P059

68 -

REV

1

DZ RIO TURBO 500BRUSHLESS DC

DZ RIO TURBO 800BRUSHLESS DC

Technical manual

3

INdEX

IMPORTANT SAFETY INSTRUCTIONS ........................................................................................ 4

TECHNICAL CHARACTERISTICS .................................................................................................. 5

TOOLS REQUIRED FOR INSTALLATION ..................................................................................... 6

TYPICAL INSTALLATION OVERVIEW .......................................................................................... 6

ELECTRICAL INSTALLATION ......................................................................................................... 7

CARE WITH ELECTRICAL INSTALLATION .................................................................................. 7

CARE WITH THE GATE BEFORE AUTOMATION ....................................................................... 8

INSTALLATION OF THE OPERATOR ............................................................................................ 9

INSTALLATION OF THE LIMIT SWITCHES ................................................................................14

TRIFLEX CONNECT BRUSHLESS BOARD ..............................................................................17

LOGICAL FUNCTION OF THE SYSTEM FOR GATES ......................................................22

PARAMETERS PROGRAMMING ..........................................................................................22

ERASE THE RECOGNIZED GATE TRAVEL .........................................................................28

APPLY FACTORY DEFAULTS .................................................................................................28

RECORD A RADIO FREQUENCY TRANSMITTER (RF) ...................................................29

SELECTION OF RF RECEPTION PROTOCOL (CF / CR) ..................................................29

DELETE ALL RF TRANSMITTERS RECORDED .................................................................29

ANTI-CRUSHING SYSTEM ....................................................................................................29

ENCODER OPERATION TEST ...............................................................................................30

EVENTS AND FAILURES INDICATIONS .............................................................................30

MAINTENANCE AND TROUBLESHOOTING ........................................................................31

EXPLODED VIEW DZ RIO TURBO 500 BRUSHLESS DC .......................................................34

EXPLODED VIEW DZ RIO TURBO 900 BRUSHLESS DC .......................................................36

EU DECLARATION OF INCORPORATION OF PARTLY COMPLETED MACHINERY

Identification Number: PPA CE 001 (Revision: 01)

Manufacturer:Company Name: MOTOPPAR INDÚSTRIA E COMÉRCIO DE AUTOMATIZADORES LTDA.Address: AV. DR LABIENO DA COSTA MACHADO, 3526 GARÇA, SÃO PAULO, 17400000 - BRASIL

Authorized Representative / Person authorized to compile the Technical File:Company Name: PERES & SELLANI S.L.Address: CARRER SALVADOR DALI, 3-1-1 SANT CUGAT DEL VALLÈS, 08173, BARCELONA - ESPAÑA

This declaration of conformity is issued under the sole responsibility of the manufacturer, which declares that:

The following partly completed machinery is the object of this declaration:Product Type: AUTOMATIC GATE OPERATOR FOR SLIDING GATESModels: DZ IND 2.0, DZ IND 1.5, DZ IND 1.0, DZ RIO 800, DZ RIO 500

The object of the declaration described above is in conformity with the following essential requirements of Directive 2006/42/EC on machinery: 1.1.1, 1.1.2, 1.1.3, 1.1.5, 1.2.1, 1.2.3, 1.2.4.1, 1.2.4.2, 1.2.4.3, 1.2.6, 1.5.1, 1.5.14, 1.5.5, 1.5.6, 1.6.1, 1.6.3, 1.7

The object of the declaration described above is in conformity with the relevant Community harmonization legislation: DIRECTIVE 2014/30/EU OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 26 February 2014 on the harmonisation of the laws of the Member States relating to electromagnetic compatibility

DIRECTIVE 2011/65/EU OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 8 June 2011 on the restriction of the use of certain hazardous substances in electrical and electronic equipment

The relevant harmonised standards considered for compliance are:

Machinery Directive (2006/42/EC):IEC 60335-1:2010+AMD1:2013 CSV/COR1:2014, IEC 60335-2-103:2015, ISO 12100:2010

EMC Directive (2014/30/EU):IEC 61000-4-2, IEC 61000-4-3, IEC 61000-4-4, IEC 61000-4-5, IEC 61000-4-6, IEC 61000-4-11, IEC 61000-4-13

RoHS Directive (2011/65/EU):EN 50581:2012

The relevant technical documentation is compiled in accordance with Annex VII, part B of Directive 2006/42/EC;

In response to a reasoned request by the national authorities, the relevant information will be transmitted;

The partly completed machinery must not be put into service until the final machinery into which it is to be incorporated has been declared in conformity with the provisions of the Machinery Directive (2006/42/EC)

GARÇA, 01/02/2019

Samuel PeresCEO

MOTOPPAR INDÚSTRIA E COMÉRCIO DE AUTOMATIZADORES LTDA.

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IMPORTANT SAFETY INSTRUCTIONS

THE FULL AUTOMATION MUST COMPLY WITH THE CURRENT EUROPEAN MACHINERY DIRECTIVE, IN PARTICULAR WITH THE STANDARDS: EN 13241-1, EN 12635, EN 60204-1, EN 12445, EN 12453, EN 12978

• Installation shall be carried out by qualifed personnel only, who can issue the Certifcate of Compliance concerning the whole installation (Machine Directive 2006/42/CE).

•Before installing the equipment, it is important that the specialist installer follow all instructions given in this technical manual and in the user manual.

•Never let children operate or play with door controls. Keep the remote control away from children. With the help of the user manual, the installer must present all information, uses and safety items of the equipment to the end user.

•Before installing the operator, make sure that the local power supply is compatible with that required on the equipment identifcation label;

•The electrical installation must be provided with a device (eg. circuit breaker) to ensure the complete disconnect of the equipment from the power supply, as well a proper cabling, grounding and residual current devices for users protection.

•The product must be installed in an environment that suits the IP rating (IPX4) of the product.

•Ensure that entrapment between the gate and the surrounding fixed parts due to the movement of the gate is avoided, according to harmonized standars (i.e. DIN EN 349, ISO EN 14120)

•The opening and closing forces should be measured and tested in accordance with BS EN 12445 (Test method) using an appropriate tool.

•Protective devices installed must comply with EN 12978 (Safety devices).

•Check the automation periodically, with special attention to cables, springs and mechanic parts for wear and tear, damages and unbalancing. Do not use the opener when service or adjustment work is required. Have a qualifed service person to make repairs to gate hardware.

•Only carry out electrical connections once the electricity supply to the system has been switched off. Disconnect any buffer batteries or Nobreaks present.

•Use the manual release only when the gate is not moving.

•Save these instructions for later reference. The original instructions are in Portuguese.

WARNING: Important safety instructions. Follow all instructions in this manual. Incorrect installation can lead to serious injury.

TECHNICAL CHARACTERISTICS

OPERATOR TYPE Sliding Sliding

MODEL DZ RIO TURBO 500BRUSHLESS DC

DZ RIO TURBO 800BRUSHLESS DC

RATED VOLTAGE 230V 230 V

NOMINAL FREQUENCY 50 Hz 50 Hz

RATED POWER Z14 = 200 WZ18 = 230 W

Z14 = 300 WZ18 = 350 W

MOTOR ROTATION Z14 = 4340 rpmZ18 = 3760 rpm

Z14 = 4515 rpmZ18 = 4200 rpm

MOTOR CURRENT Z14 = 1,5 AZ18 = 2,0 A

Z14 = 2,0 AZ18 = 2,5 A

MOTOR REDUCTION 1:36 1:36

LINEAR SPEED Z14 = 0,36 m/sZ18 = 0,47 m/s

Z14 = 0,36 m/sZ18 = 0,47 m/s

PERFORMANCE 60 cycles/h 60 cycles/h

PROTECTION DEGREE IPX4 IPX4

TEMPERATURE RANGE -20° C / +50° C -20° C / +50° C

ISOLATION TYPE Class B, 130° Class B, 130°

LIMIT SWITCH Hybrid Hybrid

MAXIMUM GATE LEAF WEIGHT 500 Kg 800 Kg

MAXIMUM GATE DIMENSIONS Height = 2,5m Length = 10 m

Height = 2,5m Length = 10 m

NOMINAL LOAD Z14= 320 NZ18= 225 N

Z14 = 505 NZ18 = 420 N

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TOOLS REQUIREd FOR INSTALLATION

Here are some tools required to install the operator:

PLIERS SAWING BOW SOCKET WRENCH SCREWDRIVER NUT WRENCH

LADDER

WELDING MACHINE HAMMER LEVEL TAPE MEASURE

FRAME DRILL PENCIL SANDER

TYPICAL INSTALLATION OVERVIEW

ITEM DESCRIPTION

1 Gate Operator

2 Rack

3 Photocells

4 Safety Edges

5 Pushbutton

6 Flashing light

7 Power supply 230V

ELECTRICAL INSTALLATION

For electrical installation, the network shall contain the following characteristics:- 230V-50Hz power supply;

The passage of the wiring must be made through conduits between:- the electrical distribution box and the total disconnect device- the total disconnect device and the operator supply terminals;- the control board and the (optional) external pushbutton;- the control board and the photocells;

The wires used must comply with the local standards. The recommended cable sizes are listed below:

DZ RIO TURBO 500DZ RIO TURBO 800 Cable Section Maximum Lenght

Power supply 230V 3 x 1,5 mm² 50 m

Photocells 2 x 0,5 mm² 10 m

Safety Edges 2 x 0,5 mm² 10 m

Pushbutton 2 x 0,5 mm² 5 m*

Flashing light 2 x 1 mm² 20 m

*For further distances, please contact technical support.

CARE WITH ELECTRICAL INSTALLATION

To avoid damage to the wiring, it is important that all conductors are properly attached to the operator. Wiring must be done through conduits, passing internally through the base of the fl oor, ensuring that none of the wiring conductors are trapped and damaged.

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It is mandatory that the ground terminal is connected to the grounding cable network.

IMPORTANTThe electrical installation must have a residual current (DR) device with a rated residual current 30 mA.

CARE WITH THE gATE bEFORE THE AUTOMATION

Before adapting the machine to the gate, check the gate movement by following the instructions below:

Step 1: Before installing the operator, check if the gate is in good mechanical condition, ie opening and closing properly. Open the gate manually and observe the required eff ort. This eff ort should be minimal for the entire length of the rail.

Step 2: Close the gate manually and check whether the eff ort was the same as the previous operation. The gate shall have a sturdy and, as far as possible, non-deformable structure. The pulleys shall have a diameter suitable to the dimensions of the gate, shall be in perfect running condition and shall be mounted in such a way that the gate leaf has stability along all its displacement. We recommend pulleys with a diameter of at least 120 mm.

The fi gures below represent the two types of rails and pulleys used. The system that uses straight section (Figure A - angle bracket) exhibits greater friction and consequently greater wear. The circular section (Figure B) allows a better displacement of the gate and less friction for the operator.

FIGURE A FIGURE B

Step 3: Check wether the gate leaf does not jam in the opening and closing movement. The slide rail of the gate must be perfectly rectilinear, leveled, and clear of any element or dirt that makes it diffi cult to slide the pulleys in their entire length.

INSTALLATION OF THE OPERATOR

Before installing the operator, remove all unnecessary cables and disable any equipment or system connected to the mains.

EQUIPMENT DIMENSIONS

Z14

= 80

Z18

= 88

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The correct operation of this equipment depends on the instructions in this manual. To secure the equipment, proceed as follows:

Step 1: Make sure the floor is firm enough so that the equipment can be screwed on a level. If it does not comply with the requirement, provide a concrete base, following the guidelines below:

Step 2: The dimensions of the base should be appropriate for the dimensions of the operator. The concrete base should be at a distance of approximately 20 mm from the face of the gate leaf.

GATE LEAF

SIDE VIEW

CONCRETE BASE

Step 3: When the conditions are fulfilled, open the gate and position the operator near the face of the gate leaf, obeying the 50 mm measurement between the leaf end and the operator.

Step 4: Pre-align the operator with the gate, positioning the rack over the gear and pushing the assembly to the gate. Then mark the fixing holes in the floor or concrete base.

MARK THE HOLES ON THE FLOOR

MARK THE FIxING HOLES ON THE FLOOR

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Step 5: Drill the holes for fastening. Place the operator aligned to the gate and insert the S 1/4” x 2 1/2” bolts without tightening them. Move the gate, making sure that it does not lean against the operation during the during its travel. If this occurs, pull back the operator.

INSERT 2 BOLTSS 1/4” x 2 1/2”

WITH S10STRADDLING

DOWEL

OPERATORFIxING HOLES

INSERT 2 BOLTSS 1/4” x 2 1/2”

WITH S10 STRADDLING DOWEL

Step 6: With the operator unlocked, position the rack bar on the gear and aligned with the gate.It is necessary to leave a gap of approximately 2 mm between the top teeth of the gear and rack bottom teeth.

2mm GAP

Step 7: Fix the rack to the entire length of the gate leaf with solder or screw every 300 or 400 mm.

300 OR400 mm

300 OR400 mm

Step 8: If the gate leaf is warped, provide shims to ensure alignment of the rack. There are cases where the rack should pass the length of the gate leaf. In this case, provide a bracket so the rack teeth will not be skipped when starting the machine.

BRACKET

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Step 9: After fixing the rack, definitely place the operator on the floor or concrete base by tightening the screws.

INSERT 2 BOLTSSS S 1/4” x 2 1/2”

WITH S10 STRADDLING DOWEL

INSERT 2 BOLTSSS S 1/4” x 2 1/2”

WITH S10STRADDLING

DOWEL

INSTALLATION OF THE LIMIT SWITCHES

Step 1: With the gate closed, place the magnet holder on the rack, positioned in front with the REED of the operator. This magnet will act as a closing limit switch.

REGULATION OF THE SUPPORT

GATE CLOSED

MAGNET SUPPORTREED SUPPORT

Step 2: Fully open the gate and place the other magnet holder on the rack, facing forward with the operator REED. This magnet will act as an opening limit switch.

REED SUPPORTMAGNET SUPPORT

GATE OPEN

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Step 3: Remove the plastic covers to gain access to the board, then operate the motor and see if the REEDs are shutting down properly. If necessary, invert the connector on the control board.After attaching the magnet holders, make fi nal adjustments by moving them to the right or left, depending on the desired setting.

Step 4: To fi nalize the installation of the operator system, it is mandatory reposition the cover and screw it with 2 self-locking screws 3,5 x 16 mm (already available on the product).

TRIFLEX CONNECT BRUSHLESS BOARD

The Trifl ex Connect Brushless board allows all parameters to be confi gured through the PROG programmer in three languages (Portuguese, English or Spanish) or trough the mobile app BLUE (In this case, it is necessary to purchase the “BLUE” module from PPA). It can control all PPA operator models with Brushless motors.It has an EEProm¹ memory that stores the codes of the Transmitters recorded in encrypted form. The board is also compatible with Rolling Code Transmitters with PPA’s own protocol.System activation can be carried out via remote control through the built-in radio receiver, a single receiver or any other device that provides a normally open (N.O.) contact, such as a push button.Trifl ex Connect Brushless is ideal for use with PPA Nobreaks. It has features for reducing consumption when operating on battery power.The gate positioning control is done through a PPA patented encoder system called “Reed Digital”.

Electrical Connections

Electrical connections can be seen in the following diagram:

¹ EEPROM (Electrically-Erasable Programmable Read-Only Memory) is a non-volatile storage chip used in computers and other devices.

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System Power

The mains connection must be made at the L and N input of the power terminal, AC connector, see figure 1.

WARNINGThe operator input voltage is 230V 50Hz.

Brushless Motor Connection

The three wires of the Brushless motor must be connected to the "MOTOR”.

Encoder “ENC” connection

It is used to connect the encoder, through an appropriate cable, between the motor and the board. Inside the operator reduction box there are sensors that have the function of providing direction of travel information and gate position during operation. Such information is essential for proper operation of the operator.

There are two sensors inside the encoder and each one is represented by the ECA and ECB LEDs. Each LED lights up according to the position of the disc.

Connection of the electromagnetic lock "LOCK"

If an Electromagnetic Lock (optional) is used, the must be connected to this connector. The board will recognize the module automatically and a time will be added to start the opening movement of the operator after the lock is activated.

Courtesy light Connection “LIGHT”

If a courtesy light is used, the “Optional Relay Module” must be connected to this connector. Courtesy light operation is always enabled. Simply set the desired time through the DIP switch according to the programming table in this manual.

Separate receiver connection "REC"

A separate receiver can be added to the board via the "REC" connector. When a command is accepted, the CMD LED (command) is triggered. The ENRF Jumper must be removed when the single receiver is added to the system in order to turn off the built-in receiver.

NOTE: Before connecting the optional accessories (Electromagnetic Lock and / or Garage Light / Signal, pushbuttons and etc.), it is advisable to carry out a general test of machine operation. To do this, simply press the “+” button to activate the gate travel recognition cycle.

Safety Inputs for Closing and Opening - “SFC” and “SFO”

The SFC input stops the closing movement and reverses the gate. The SFO input causes an immediate stop (with a short reverse) of the gate opening movement. These inputs support safety devices like photocells and safe edges with normally open “NO”, normally closed “NC” contacts, as well as devices with 8.2 kΩ constant resistance output. The safety condition provided by the device(s) is recognized by the control board so that when there is a variation on this safety condition, the movement stops and reverses.It is possible to arrange multiple devices, respecting some conditions, as described next:

• Multiple NO devices can be connected to each other in parallel without restriction.

• Multiple NC devices can be connected to each other in series without restriction.

• Devices with 8.2 kΩ constant resistance output can be connected in parallel; • It is also possible to combine NO and NC devices in parallel, using an 8.2 kΩ

resistor in series with the NC contact.

IMPORTANTIn order to comply with category 2 or 3 of EN ISO 13849-1, only devices with 8.2 kΩ constant resistance shall be used.

Photocell should be installed at a height of about 50 cm from the floor (or as recommended by the manufacturer) and installed so that transmitter and receiver are aligned with each other. The electrical connection should be made as follows:

Terminal 2: 15V (positive “+”);Terminal 1: GND (negative “-”);Terminal 4: SFC (Photocells or Safety Edges on the closing direction);Terminal 6: SFO (Photocells or Safety Edges on the opening direction).

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Pushbutton Connection “PBU”

The board recognizes a button control when the PBU terminal is connected to the GND, ie a pulse for GND.

Terminal 1: GND (-);Terminal 4: PBU (Normally Open Contact - N.O.).

Pushbutton Connection for only opening “OPE”

The board recognizes an opening command when the OPE terminal is connected to the GND, ie a pulse for GND.

Terminal 1: GND (-);Terminal 5: OPE (Normally Open Contact - N.O.).

Pushbutton Connection only for closing "CLO"

The board acknowledges a closing command when the CLO terminal is connected to the GND and then released, ie a pulse for GND and then the button must be released.

This can also be used in access control systems that use photocells or inductive loops to automatically close the gate or barrier.

Terminal 1: GND (-); Terminal 6: CLO (Normally Open Contact - N.O.).

ATENTION: The Control Board provides 15 V (maximum continuous current of 120 mA) for powering photocells and receivers AND DOES NOT HAVE OVERCURRENT PROTECTION. If the external optional equipments require more voltage or current, it will be necessary to use an auxiliary power supply.

Connection of reed sensors limit switch “MGS”

The control board acknowledges an activated ‘reed’ when the pin corresponding to it on the MGS pin bar is connected to the GND, i.e., a pulse to the GND.The only condition that must be followed is that the reed that represents the open gate must be connected in such a way that the ‘MSO’ LED lights. And the ‘MSC’ LED must light when the gate is closed.

“PROG” Connection

External communication connector on control board for use with PROG or BLUE.

“UPS_C” Connection

This connector is the communication between the board and the PPA Nobreaks. With this connection installed, the board optimizes operation when it is operating without power from the mains, ie by the batteries.

What is optimized:

1 - The board reduces the power consumption when the engine is switched on by reducing the work speed, saving up to 50% on battery;

2 - When the control board is in standby, with the gate open or closed, the motor is off. The control board then sends a command to the PPA Nobreak to turn off the power control stage and reduce the battery consumption, increasing the autonomy. With this feature, main power may be disconnected for several hours without completely draining the battery. Only the RF receiver and the controls are energized directly by the battery, which allows the control board to receive a command and only after that the PPA Nobreak reconnects the power control stage and the operator starts the movement. This system is patented by PPA.

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LOGICAL FUNCTION OF THE SYSTEM FOR GATES

First operation after installation (gate travel recognition)

When the control board is powered up for the first time, after the operator being properly installed, the gate should start an opening movement after an external command or if the ‘+’ button is pressed.If instead the gate starts a closing movement, remove the ‘F/R’ jumper to change the direction of the motor. After removing the jumper the gate will stop. Press the ‘+’ button again or proceed with an external command. The gate should start opening. Let the gate reach the opening physical stop or the REED A (magnet limit switch) is activated. Then, it will automatically reverse the movement direction to close; let it reach the closing physical stop or activate the closed REED F.

NOTE: The operator can work with encoder (digital) or either encoder + reed (hybrid), but cannot work only with a reed.During the travel recognition only the obstruction of the external entrapment protection device can reverse the gate movement direction.

Gate Operation after a power cycle (travel recognized)

After the previous operation, the gate does not need to recognize the travel again. When the inverter is powered up, the gate simply closes slowly after a command (‘+’ button or external one), until it reaches the closing physical stop. The motor will turn off and the operator is ready to use again.

If the photocell is obstructed or the board receives a command during this first closing, the gate movement direction will be reversed and, in this case, when the gate is fully opened the operator is ready to use.

PARAMETERS PROGRAMMING

Operator Model Selection

The board can operate, with the same firmware, on gates and barriers.To select the desired model, simply remove the TST jumper and close the B/G

(Barrier / Gate) pins. When the function is selected, the “OSC” LED flashes rapidly for short time interval and then indicates the parameter value.

The following table shows the number of blinks for each function:

NUMBER OF FLASHES REFERENCE MODEL

1 LIGHTWEIGHT GATE (RESIDENCIAL)

2 HEAVY GATE (INDUSTRIAL)

3 BARRIER 3M (BARRIER UP TO 3M IN LENGTH)

4 BARRIER 6M (BARRIER ABOVE 3M TO 6M IN LENGTH)

5 NON STOP BARRIER (SPECIFIC PPA BARRIER MODEL)

The pause before repeating the parameter value is three seconds and the flashes indicating the parameter value occur every half second, so they are very different.

To increase the values, simply press the plus (+) button and to decrease, simply press the minus (-) button.

When you reach the desired model, return the B/G jumper to the TST position. Once this is done, the board is ready to operate on the chosen operator model.

NOTE: For the DZ Concominium operator or higher model, use the “Heavy Gate” parameter in this function.

TST jumper Function

When the TST jumper is removed, the control board enters a mode of operation that allows to position the operator at any point of its travel path to adjust the limit switches or to check the mechanical part.

In this operating mode, when the (-) button is pressed, the motor is activated in a clockwise direction while the button is pressed, when the motor is released, the motor shuts off, and when the (+) button is pressed, it is activated counterclockwise.

Adjustment of other parameters

The control board also has other functions controlled by the DS1 dip switch. When a function is selected, the ‘OSC’ LED flashes rapidly for a specific period of time and then indicates the parameter value. When the ‘OSC’ LED flashes each half second (0.5s), the minimum value is selected; when it is off, an intermediate value is selected and when it keeps lit, the maximum value is selected.

In order to increase the values, just press the ‘+’ button; to decrease the values, just press the ‘-’ button when the desired function is selected.

When leaving the function, the ‘OSC’ LED rapidly blinks again for a specific period of time, and when all DIPs are off it blinks in a one-second interval again.

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Programming Functions Table:

Function Description

“_” or “REC” (DIP 1)

1 2 3 4 5 6 7 8

ON

FUNCTION SELECTOR / RECORD OR DELETE TRANSMITTERS (TX)When combined with other DIPs, it enables the edit of the under-lined parameters.When only the DIP 1 is activated, the board is ready to record or delete (TX) transmitters.

Record TX: press the desired transmitter button after you have acti-vated this DIP, note that the OSC LED flashes fast if are receiving the signal and then press the (+) button on the board to record. Note that the OSC LED lights up when receive a sinal already recorded on the board. Delete: To delete the RF transmitters stored in the memory, press the Triflex (-) button and the (+) button simultaneously for 10 se-conds, note that the OSC LED will blink every 1s and after 10s the LED OSC for the count at that time all recorded transmitters have been deleted.

“PTA” (DIP 1 and 2)

1 2 3 4 5 6 7 8

ON

SEMIAUTOMATIC FUNCTION / PAUSE TIME IN THE AUTOMATIC MODEPress “+” button for incrementing the pause time.Press “-“ button for decrementing the pause time.

Gate: Increases or decreases time by two seconds (2s) from zero (0s) two hundred and forty seconds (240s), when the zero value is selected, the operator becames semiautomatic.Barrier: Increases or decreases time by one second (1s) from zero (0s) to two hundred forty seconds (240s), when the zero value is selected the operator becomes semiautomatic.

“CLS” (DIP 1 and 3)

1 2 3 4 5 6 7 8

ON

CLOSING END OF TRAVEL ZONE Increases or decreases the distance in which the operator starts to slow down when closing.It is recommended to set the deceleration ramp so that the gate moves at end of travel speed by at least 50 cm before full closing.

“OLS” (DIP 1 and 4)

1 2 3 4 5 6 7 8

ON

OPENING END OF TRAVEL ZONE Increases or decreases the distance in which the operator starts to slow down when opening.It is recommended to set the deceleration ramp so that the gate moves at end of travel speed by at least 50 cm before full opening.

“GSS” (DIP 1 and 5)

1 2 3 4 5 6 7 8

ON

GATE: HOW TO ADJUST THE GAP BETWEEN GATE AND ITSMECHANICAL STOPIf necessary, the space between the stop and the gate can be adjusted when the operator completes the closing or opening cycle. It can be closer or far from the stop.The minimum value of 0 (LED flashes), increment and decrement from 1 to the maximum value of 10 (LED lit).Important: To test the changes, it is necessary to operate the gate once, so that the operator system performs an opening and closing cycle.

BARRIER: SET THE BARRIER TO CLOSE AUTOMATICALLY WHEN ENERGIZEDPress the (-) button to turn off (LED flashing) the function or the (+) button to activate it (LED on).When this function is enabled, the barrier automatically initiates the closing movement after a power-up. If there is any command to open, for example, FOT, BOT, ABR and etc., the gate initiates an opening movement.Also, this function CONFIGURES THE “LIGHT” AND “LOCK” OUTPUTS TO OPERATE AS “CLOSING BARRIER” AND “OPENING BARRIER” SIGNALING, RESPECTIVELY.

“MPA” (DIP 1 and 6)

1 2 3 4 5 6 7 8

ON

GATE: HOW TO DECREASE OR INCREASE MOTOR STRENGTH DURING TRAVEL RECOGNITION.If necessary, it is possible to decrease the motor force during the travel recognition, for example, to avoid that the rack bar breaks.It is also possible to increase the strength, if necessary.Press the ‘+’ button to increase the strength and the ‘-’ button to decrease it.The minimum level is 40% (LED blinking) and it is increased by four levels at a time (4%) up to the maximum 100% level (LED lit).

“PCF” (DIP 1 and 7)

1 2 3 4 5 6 7 8

ON

GATE AND BARRIER: ENABLE PHOTOCELL ‘FOLLOWER MODE’In some facilities, such as a comdominium, it is necessary that the gate closes automatically as soon as the vehicle gets out from the gate path. In order to do so, there must installed a photocell and the “follower” (aka mirrored) function must be enabled.Press the ‘+’ to enable it and to include the period of time before the automatic closing.The minimum value is zero (0 – LED blinking) and it is increased by one second at a time (1) up to its maximum 60-second value (LED lit).

Example: LED blinking (function disabled). When pressing the ‘+’ button once, the LED is turned off and the “follower” mode is enabled. The pause time before the automatic closing starts is zero (0) second. If the button is pressed once more, the pause now is one (1) second, and so on, up to sixty (60) seconds, when the LED lits.

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“SF” (DIP 1 e 8)

1 2 3 4 5 6 7 8

ON

CONFIGURING SAFETY DEVICESIt reads the current state of the SFO and SFC inputs and stores the value as a safe condition.To store the safety condition: Press the (+) button and wait for the OSC led to light up.IMPORTANT: Before reading the inputs of the safety devices, make sure that the entire system is installed, connected and that the devices are NOT actuated.IMPORTANT: After setup it is extremely important to test the operation of all safety items that are connected to the operator.

“LGT” (DIP 2)

1 2 3 4 5 6 7 8

ON

COURTESY LIGHT TIME / PRE-FLASHING TIMESelects the time the “LUZ” output is activated after the gate is closed. The adjustment step is five seconds (5s), with values from zero (0) to two hundred and forty seconds (240s). This output is automatically activated when any key of the DIP switch is triggered or the recognition process is started.Note: When using a time between 0 and 235 seconds (or 239, if programming is via PROG), the “LUZ” output will be activated while the gate is open, opening and closing. When the closing is complete, the control unit will decrease the programmed time and turn off the output when it reaches zero.When the function value is set to 240s, the “LUZ” output will work in the “traffic light function”, the “LUZ” output indicates that the traffic is released (green light) and the “TRAVA” output indicates that the traffic is blocked (red light). The red light is activated for two seconds (2 seconds) before the gate starts the closing movement when it is in automatic mode and remains active throughout the closing until the gate is fully closed. The green light is activated with the gate opening and also in the open state.If the set time is greater than 240s, the “Pre-flashing Time” function will be enabled and the waiting time before starting the opening cycle will be adjustable in 5 second steps from 0 to 15s (when the parameter will be 255s). With the PROG the time can be adjusted with one second steps (1s). In addition, the PROG display informs you whether the “traffic light” function or the “Pre-flashing Time” function is enabled.

“SLS” (DIP 3)

1 2 3 4 5 6 7 8

ON

END OF TRAVEL SPEEDSpeed when the gate is next to a travel limit switch (open or closed).•Switch3on“ON”position(“VFC”);•Button“(+)”increasethespeed;•Button“(-)”decreasespeed;In gates the adjust step is 5Hz, from 15Hz to 30Hz.In barrier the adjust step is 1Hz, from 4Hz to 20Hz.

Obs.: The travel recognition speed is equal to the end of travel speed if it is greater that 20Hz, if it is smaller, the board automatically uses 20 Hz during travel recognition.

“SPD” (DIP 4)

1 2 3 4 5 6 7 8

ON

GATE: ADJUSTING THE OPENING AND CLOSING SPEED•SwitchDip4to“ON”(“VFC”)position;•The“(+)”buttonincreasesthespeed;•The“(-)”buttondecreasesthespeed;

Note: the adjust step is 10Hz, from 60Hz to 180Hz. It is possible to adjust the opening and closing speeds individually, however this setting is only available via the PROG keypad, for more information please refer to the manual of this product. When programming Triflex Connect BRUSHLESS control board via DIP switch, this is not supported.

BARRIERS: ADJUSTING THE OPENING SPEED•Dip 4 to “ON” (“VEL”);•“(+)”Buttonincreasesthespeed;•“(-)”Buttondecreasesthespeed;

Note: The adjust step is 2Hz, from 20Hz to 80Hz.

“REV” (DIP 5)

1 2 3 4 5 6 7 8

ON

GATE: DISABLE “STOP” COMMAND DURING OPENINGWhen the operator is installed in condominiums it may be necessary to disable the function that stops the gate when receiving a command during the opening.Press the (-) button to disable (LED blinking) or the (+) button to enable (LED on).

BARRIER: CHANGE THE CLOSING SPEEDTo change the closing speed, press the (-) button to decrease and the (+) button to increase. The minimum value is 20Hz (OSC LED flashing), increase by 2Hz to the maximum value of 80Hz (LED OSC on).

“STG” (DIP 6)

1 2 3 4 5 6 7 8

ON

GATE: ADJUSTING THE “STRENGTH” OF THE OPERATORThe operator, by default, has its strength set to the maximum value. It is possible to decrease it ifnecessary. Press ‘-’ button to decrease the strength and ‘+’ to increase it.The minimum level is 40% (LED blinking) and the adjust step is (4%) up to the maximum level, 100% (LED lit).If the strength is in a very low level, the gate operator won’t work at full speed.

28 29

Press the (-) button to turn off (flashing LED) the open stop function or the (+) button to activate (LED on); When the (+) button is pressed again, the blue LED goes off indicating the “delay only” option enabled. In the “Delay only” option, the gate must abort the command after another command only if it has not started the movement, ie during the aperture delay, then it should open without being able to stop.

BARRIER: CONFIGURE “BOT” AS COMMAND ONLY FOR OPENINGWhen this function is activated, the BOT input becomes an open-only command.Press the (-) button to turn off (LED flashing) the function or the (+) button to activate it (LED on).

“STS” (DIP 7)

1 2 3 4 5 6 7 8

ON

GATE: START SPEED OF THE GATEPress the (-) button to decrease and the (+) button to increase.The minimum value is 20Hz (OSC LED flashing) with an increment step of 10Hz, up to the 60Hz (LED OSC on) maximum value.

BARRIER: SET THE “LIGHT” AND “LOCK” OUTPUTS TO OPERATE AS “CLOSING BARRIER” AND “OPENING BARRIER” SIGNALING, RESPECTIVELY.

Press the button (-) to turn off (LED flash) the function or the button(+) to enable (LED lit).

“LCK” (DIP 8)

1 2 3 4 5 6 7 8

ON

GATE: Press the button (+) to enable the pulse for a magnetic lock when the gate is closing (LED ON). Press (-) to turn off (LED flashing).

ERASE THE RECOGNIZED GATE TRAVEL

In order to erase the acquired path, simply press both ‘+’ and ‘-’ buttons at the same time and keep them pressed until ‘OSC’ LED lits. When the buttons are released, the acquired path is already erased.

NOTE: All keys of the “DIP Switch (DS1)” must be turned off.

APPLY FACTORY DEFAULTS

To return the factory settings to all functions, simply press the “(+)” and “(-)” buttons

at the same time and hold them down until the “OSC” LED lights up. Keep them pressed until the LED “OSC” flashes. When the buttons are released, the travel is deleted and the factory settings are applied.

RECORD A RADIO FREQUENCY TRANSMITTER (RF)

In order to record an RF transmitter, slide the dip #1 of the DS1 dip switch to “on” position, press the button of the transmitter to be recorded and keep it pressed for at least two seconds. Next, press the ‘+’ button on the triflex control board. Note that before the transmitter has been added, the ‘OSC’ LED blinks rapidly. After it is recorded, the ‘OSC’ LED keeps on during transmission. Up to 328 transmitters can be recorded in Fixed Code (CF) mode and 164 transmitters on Rolling Code mode (see next section).

SELECTION OF RF RECEPTION PROTOCOL (RC/FC)

To select the reception protocol as Fixed Code (FC) mode, simply open the jumper labeled “RC/ FC”. To select the Rolling Code (RC) mode, simply close the jumper “RC / FC”.

WARNING: Every time this confguration (reception protocol) is changed, all the recorded remote controls must be erased. For more information, see the next topic: “Erasing all stored remote controls”.

DELETE ALL RF TRANSMITTERS RECORDED

In order to erase all remote controls stored on the board memory, slide the dip #1 of the DS1 dip switch to ‘on’ position, press both ‘-’ and ‘+’ buttons of the control board at the same time for 10 seconds - observe that the ‘OSC’ LED blinks once a second and after the 10-second period the LED stops blinking. This means all added transmitters have been erased.

ANTI-CRUSHING SYSTEM

The anti-crushing feature allows the operator to detect the presence of obstacles in the gate path. In the normal operating cycle, if an obstacle is detected, the system will take the following actions:a) When closing: the gate will be activated in the opening direction.b) When opening: the engine will shut down and wait for some command to start the closing.c) When recognizing the travel: the anti-crushing feature only has the function of recognizing the opening and closing limits, ie the point of the path where an obstacle was detected will be interpreted as a limit switch.

30 31

WARNING: Depending on the installation, this anti-crushing system is not enough to comply with EN13241, EN12978 and EN12453, and to avoid accidents with people and animals, requiring the use of photocells and safety edges.Even using the inherent anti-crushing system, it is recommended to use passive edges for better performance and protection.

ENCODER OPERATION TEST

It is possible to test the encoder of the operator by connecting it to the board and checking if the “ENC” LED is flashing when the operator is moved.

EVENTS AND FAILURES INDICATIONS

Microcontroller operation indication

The main function of the “OSC” LED is to indicate that the controller board is operating. It flashes with a fixed frequency of ~ 1 Hz, since the power is turned on.

Motor over current or short circuit

The “OSC” LED flashes rapidly (in a 0.1- second interval) to warn that the power stage has tripped due to overcurrent or short circuit in the motor. The board may operate normally after 10s of the occurrence of the overload.

Overheating

The “END” LED flashes rapidly, in a 0.1-second interval, to warn that the power stage has tripped due to overheating of the heatsink of the environment. The operator can only be operated again if the temperature decreases to less than 100ºC.

EEPROM fault

The “OSC” LED flashes twice when Memory is not present.

EEPROM with invalid data

The “OSC” LED flashes three times when Memory is present but it has a content that the microcontroller does not identify as a Valid Transmitter Code.

MAINTENANCE ANd TROUbLESHOOTINg In the table below are found some PROBLEMS - DEFECTS, PROBABLE CAUSES AND CORRECTIONS - which may occur in the operator. Before any maintenance, it is necessary to completely disconnect the power grid.

Open limit switch

The “END” LED flashes when the gate reaches an open limit switch.Closed limit switch

The “END” LED is lit when the gate reaches a closed limit switch.

Load in the capacitors

The “BUS” LED indicates that there is load on the power stage capacitors.

WARNING: The power region (capacitor region) of the board must not be touched while this LED is lit even after the inverter is disconnected from the electricity grid!

Command

The “CMD” LED on indicates that the control panel is receiving some command from the digital inputs, such as OPE, CLO, PBU, SFO or SFC.

DEFECTS PROBABLE CAUSES CORRECTIONS

Motor does not start / does not move

A) Power grid off A) Make sure the power grid is turned on correctly

B) Open/ Burned fuse

B) Replace fuse with the same specification

C) Locked gate C) Make sure that there are no objects blocking the gate operation

D) Limit switch with defect.

D) Replace the limit switch system (analog and / or digital)

32

Motor blocked

A) Inverted motor connection

A) Check the motor wires

B) Locked gate or motor

B) Manually unlock the operator and check individually the gate movement and the motor operation

Electronic board does not accept command

A) Burned fuse A) Replace the fuse

B) Power grid off (power)

B) Connect the power gird (power)

C) Low battery on the remote control

C) Check and replace the battery

D) Transmitter range (remote control)

D) Check the position of the receiver antena and, if necessary, reposition it to improve the range.

Motor only turns to one side

A) Inverted motor wires

A) Check the motor

B) Inverted limit switch system

B) Invert the limit switch connector (analog and / or digital)

C) Defect in the commanc board

C) Replace the board

The gate does not correspond to the path

of the place where the operator has been

installed (it brakes before it reaches the stop or slams when closing).

The recorded path is different from the place where the operator has been installed.

Press both ‘+’ and ‘-’ buttons at thesame time and keep them pressed until ‘OSC’ LED lights up.

Gate remains open and when it receives

commands to open, it closes.

Travel recognizing was not performed correctly.

Refer to item: First operation after installation (gate travel recognition)

LED “OSC” flashesQuickly and the motor

Turns off.

Current sensor activated. this may happen when the motor has a malfunction.

Check the stator resistance. check the motor current (it must be less than 3A rms with 5A rms peak current - 2s maximum).

34 35

EXPLOdEd VIEW

DZ RIO TURBO 500 BRUSHLESS DC

ITEM QTY CODE PARTS DESCRIPTION

1 1 A17507 UNIVERSAL ENCODER SET

2 1 A17503 Z18 OUTPUT SHAFT SET

2 1 A17504 Z14 OUTPUT SHAFT SET

2.1 2 C10197 6203 ZZ BEARING

2.2 1 C10779 M5 X 25MM TORX SCREW

2.3 1 C27619 6 X 6 X 31 KEY

2.4 1 P00918 Z23 GEAR RING WITH ALUMINIUM HUB

2.5 1 P01200 Z18 GEAR - RESIDENTIAL LINE

2.5 1 P01412 Z14 GEAR - RESIDENTIAL LINE

2.6 1 P01266 UNLOCKING SPRING

2.7 1 P01421 OUTPUT SHAFT

2.8 1 P01481 UNLOCKING PLASTIC PIN

2.9 1 P05905 BUSHING NYLON unlocking HOME (EC)

2.10 2 P13866 17MM NYLON BUSH CASING

2.11 1 P13869 Ø5 X 21 BUSH PIN

2.12 1 P15560 UNIVERSAL ENCODER DISC SET

3 1 A17505 1,5 M RACK BARS

3.1 15 C10493 M5 X 12 FLANGED SCREW

3.2 3 P05902 RACK PIECE

3.3 1 P02931 RACK BRACKET

4 1 A17173 230V 50HZ BRUSHLESS DC STATOR

5 1 A22107 CONTROL BOARD TRIFLEX CONNECT BRUSHLESS DC 230V 50HZ

6 4 C10003 ¼" WASHER

7 6 C10254 3,9 X 9,5 PHILIPS SCREW

8 1 C10347 5.2 TERMINAL EYE

9 1 C10778 M5 X 10MM TORX SCREW

10 1 C10779 M5 X 25MM TORX SCREW

11 5 C10833 M5 X 20MM TORX SCREW

12 4 C10859 M5 X 70MM TORX SCREW

13 2 C11041 7MM X 14MM x 50MM MAGNET

14 4 C20204 3 X 6MM PHILIPS SCREW

15 2 CC00100 3,5x16 SELF-TAPPING SCREW

16 1 P05894 GEAR PROTECTION

17 1 P01195 CONTROL BOARD BASE

18 1 P05895 CONTROL BOARD COVER

19 1 P01197 ENCODER COVER

20 1 P01213 RETAINING RING

21 2 P01264 REED BRACKET

22 1 P04437 MOTOR UNDER BASE

23 1 P04438 MOTOR UPPER COVER

24 1 P04439 MOTOR UPPER BASE

25 1 P04440 UNLOCKING HANDLE SET

25.1 1 C10963 STEEL LOCK 1/2 THREAD ( PAPAIZ 511 + M20 )

25.2 1 P04441 UNLOCKING HANDLE

26 2 P04685 MAGNET PLASTIC BRACKET

26.1 1 P04686 FIXED BASE FOR MAGNET PLASTIC BRACKET

26.2 1 P04687 ADJUSTABLE BASE FOR MAGNET PLASTIC BRACKET

27 1 P04768 ROTOR SHAFT

28 1 P10526 LIMIT REED

29 4 P14199 1/4" X 2 1/2" SCREW

30 4 P14200 S10 BUSHING

31 1 P19642 REED BRACKET

36 37

EXPLOdEd VIEW

DZ RIO TURBO 800 BRUSHLESS DC

ITEM QTY CODE PARTS DESCRIPTION

1 1 A17507 UNIVERSAL ENCODER SET

2 1 A17503 Z18 OUTPUT SHAFT SET

2 1 A17504 Z14 OUTPUT SHAFT SET

2.1 2 C10197 6203 ZZ BEARING

2.2 1 C10779 M5 X 25MM TORX SCREW

2.3 1 C27619 6 X 6 X 31 KEY

2.4 1 P00918 Z23 GEAR RING WITH ALUMINIUM HUB

2.5 1 P01200 Z18 GEAR - RESIDENTIAL LINE

2.5 1 P01412 Z14 GEAR - RESIDENTIAL LINE

2.6 1 P01266 UNLOCKING SPRING

2.7 1 P01421 OUTPUT SHAFT

2.8 1 P01481 UNLOCKING PLASTIC PIN

2.9 1 P05905 BUSHING NYLON unlocking HOME (EC)

2.10 2 P13866 17MM NYLON BUSH CASING

2.11 1 P13869 Ø5 X 21 BUSH PIN

2.12 1 P15560 UNIVERSAL ENCODER DISC SET

3 1 A16348 230V 50HZ BRUSHLESS DC STATOR

4 1 A17505 1,5 M RACK BARS

4.1 15 C10493 M5 X 12 FLANGED SCREW

4.2 3 P05902 RACK PIECE

4.3 1 P02931 RACK BRACKET

5 1 A22107 CONTROL BOARD TRIFLEX CONNECT BRUSHLESS DC 230V 50HZ

6 4 C10003 ¼" WASHER

7 6 C10254 3,9 X 9,5 PHILIPS SCREW

8 1 C10347 5.2 TERMINAL EYE

9 1 C10778 M5 X 10MM TORX SCREW

10 1 C10779 M5 X 25MM TORX SCREW

11 5 C10833 M5 X 20MM TORX SCREW

12 4 C10859 M5 X 70MM TORX SCREW

13 2 C11041 7MM X 14MM x 50MM MAGNET

14 4 C20204 3 X 6MM PHILIPS SCREW

15 2 CC00100 3,5x16 SELF-TAPPING SCREW

16 1 P05894 GEAR PROTECTION

17 1 P01195 CONTROL BOARD BASE

18 1 P05895 CONTROL BOARD COVER

19 1 P01197 ENCODER COVER

20 1 P01213 RETAINING RING

21 2 P01264 REED BRACKET

22 1 P03218 ROTOR SHAFT

23 1 P04437 MOTOR UNDER BASE

24 1 P04438 MOTOR UPPER COVER

25 1 P04439 MOTOR UPPER BASE

26 1 P04440 UNLOCKING HANDLE SET

26.1 1 C10963 STEEL LOCK 1/2 THREAD ( PAPAIZ 511 + M20 )

26.2 1 P04441 UNLOCKING HANDLE

27 2 P04685 MAGNET PLASTIC BRACKET

27.1 1 P04686 FIXED BASE FOR MAGNET PLASTIC BRACKET

27.2 1 P04687 ADJUSTABLE BASE FOR MAGNET PLASTIC BRACKET

28 1 P10526 LIMIT REED

29 4 P14199 1/4" X 2 1/2" SCREW

30 4 P14200 S10 BUSHING