INSTALLATION OF UP-AND-OVER GARAGE DOORS

CLARIFICATION

Following points clarify some step relevant to installation of actuators for UP-AND-OVER GARAGE DOORS.
As an instance please note:

Every technician will read the Europe regulations as issued by CEI or UNI.
All information provided by manufacturers (as we are) ARE NEVER complete nor exhaustive, and could in some instance be misleading

ASSESSMENT OF COMPLIANCE
In accordance with regulation EN13241-1 (Industrial doors and gates, commercial and garage items) the assessment of compliance (6.1) for a gate, with or without actuator, may be performed by an independent institute on a sample basis, upon request by the manufacturer (6.2), or may be performed directly by the installation personnel through on-site verifications (6.3).
On-site verifications will ensure the actuated gate complies with regulations EN12604 and EN 12453.

VERIFICATION OF THE UP-AND-OVER GARAGE DOOR (EN12604 “Industrial and commercial closing systems, for garages and gates – Mechanical details)

  1. Before fitting an actuator to a UP-AND-OVER GARAGE DOOR, the latter must comply to regulation EN12604, irrelevant of the manufacture date.
    In case the gate is very old and does not comply with applicable regulations, it must be updated to conform to the regulation requirements BEFORE the actuator installation. I.e. in case the wires are seized or worn, they MUST BE REPLACED!
    The Europe regulation EN12604, step 4.3 “protection against unintentional and uncontrolled movement”, requires, beyond other things, that:
  2. The balancing system of the UP-AND-OVER GARAGE DOORS must provide correct balancing in every position, and in any case the unbalancing will not result in a static effort greater than 150N (15,3 kg) on the closing edge. Verify by unlocking the actuator
  3. In case of a spring seizure, the gate unbalancing will not exceed 200n (20,4 kg), even following unlocking of the actuator to revert to manual operation. Following such operation it is mandatory to reset the correct balancing of the gate. It is therefore advisable to distribute the weight of the UP-AND-OVER GARAGE DOOR  over a suitable amount of springs, or to provide the gate with a drop prevention system.
    NOTE: According to the regulation EN12604, para. 4.3.4, in case step 3 is complied to, the gate does not need to be fitted with a drop prevention system.
  4. the UP-AND-OVER GARAGE DOOR must be driven to the end stroke positions avoiding bumping (EN12604 para. 4.3.1). NOTE: Installation of an actuator without a correct setting of  stroke end devices, entails a sequence of unintended shocks on the actuator components and on gate structure, bound to affect the safety of the unit. AVOIDING STROKE ENDS SETTING TO SHORTCUT THE ASSEMBLY PROCEDURE, IMPLICITELY IMPLIES THE NON COMPLIANCE OF THE ASSEMBLY!!
  5. The manufacturer of the UP-AND-OVER GARAGE DOOR must specify the design life of the unit, as full operating cycles. Scheduled maintenance and replacements must be clearly indicated on an easy accessible area of the unit
  6. To perform a safe manual movement of the UP-AND-OVER GARAGE DOOR, it is necessary to verify that:
  7. the gate features suitable handles
  8. such handles are positioned as not to become danger spots during operation
    the manual effort to operate the gate will not exceed 225N (about 22 kg) for units installed on house applications, and 390n (about 39kg) for units installed on commercial and industrial applications (figures specified at para. 5.3.5 of regulation EN12453)
    CAUTION: unlocking of the unit can induce an uncontrollable movement of the UP-AND-OVER GARAGE DOOR in case the latter has not been correctly balanced.
  9. Before installation, the personnel will remove all unnecessary ropes or chains, and disable all equipments not strictly required after the installation of the drive motor.
  10. Before the installation of the drive motor, the personnel will ensure that the UP-AND-OVER GARAGE DOOR is in good mechanical condition, and can be opened and closed correctly.
  11. The installation personnel will fit the device for manual release at an height lower than 1,8 mt.
  12.  The installation personnel will remove any obstacle to the movement of the gate (i.e. locks, stops)

AUTOMATIC UP-AND-OVER GARAGE DOOR

  1. A UP-AND-OVER GARAGE DOOR can be automated only if in compliance with regulation EN12604.  Differently it must be modified to comply before proceeding with actuator installation.
  2. In case an installation with remote radio control or anyhow in UNMANNED CONDITION is sought, on completion of installation the personnel will ensure that the drive motor will prevent or stop the opening movement when the gate is loaded with a 20kg weight, applied to the centre of the door lower edge (for gates exceeding an opening of 50mm diameter) (regulation EN 12445 “ Industrial and commercial closing systems, for garages and gates –Safety in the use of automatic closures, test methods”, para. 4.1.2 “safety against raise risk with unmanned control” specifies that the UP-AND-OVER GARAGE DOOR will not be able to raise a weight greater than 20 kg).
  3. To comply with limits of regulation EN12453, in case during the movement the peak effort exceeds the limits of 400 N it is necessary to provide an obstacle monitoring over the whole gate heigth (up to 2,5 mt). In this case the photocells will be installed as specified by regulation EN 12445, para. 7.3.2.2
  4. Before the installation, the personnel will perform a thorough risk assessment on the automated closure, and a safety correction of the risk area as identified (in accordance with regulations EN12453/EN12445)
  5. In compliance with the regulation EN12453, step 5.5.2    The non automated doors (automated closure not activated) unifamiliar, featuring an actuator in compliance with EN60335-2-95:2001 and not facing areas open to public, do not need to be fitted with devices for crushing, cutting or dragging protection, as per Page 6 of 28.
  6. The installation personnel will issue to the end user a user manual in accordance with regulation 12635. IT WILL NOT BE THE MANUAL ISSUED BY RIB!
  7. The installation personnel will place a set of safety labels in vicinity of the gate controls, in a visible area. Such labels will warn against the risk trapping or crushing. LABELS ARE SUPPLIED BY RIB WITH EVERY ACTUATOR.
  8. The system must be checked frequently, typically the ropes, springs and supports, to detect any unbalancing, wear or damages. The end user will not electrically operate the UP-AND-OVER GARAGE DOOR in case of maintenance or repair, since a system failure or an out of balance door can cause injuries.
  9. The installation personnel will provide a technical brochure, as requested by Machines Regulation  98/37/EEC and regulations 93/68/EEC - 73/23/EEC - 89/336/EEC - 92/31/EC.
  10. The connection of the electrical components, outside the actuator (i.e. photocells, flashers…) will be performed in accordance with regulation EN60204-1 and following amendments from step 5.2.2 of regulation EN 12453
  11. In case a deeper knowledge of regulations applicable to UP-AND-OVER GARAGE DOORS is sought, the following is the list of most significant documents to be purchased

EN 12453 2000
EN 12445 2002
EN 12604
EN 12605
EN 12635
EN 13241-1
EN 60204-1
EN 60335-2-95

The complete list of specifications can be found on the compliance statement of the unit, on the actuator manual.

Implementation of the European standard EN 13 241-1 of 1st May 2005.

Reference used to write this article:
The Webseite of the European Association of the manufacturers of doors
The Webseite of APN advice and training
AFNOR norme en français
Web site EBC (European Builders Confederation)
ABD Europe Private Company

1. THE MAIN POINTS :
The standard EN 13 241-1 is based on a sequence of 19 Norms !! , which deals with industrial, commercial, residential or collective, manual or motorized doors, gates, railings, roller shutter and rising gates.
The standard allows to all parties involved, consumers, manufacturers, installers,controlling bodies and assurances, to have a unique reference in whole Europe :
- Criteria of performance and closing resistance of portals.
- Criteria of acoustic and thermic isolation.
- Criteria of installation and criteria of mecanic and electric security.
- Responsibility of the installer, criteria of use of this product.
- Terminology and definition of used terms in the standard.
- The definition of tries for the justification of performances listed above.

2. THE DIFFERENT ACTORS AND THEIR RESPONSABILITIES.

 THE ACTORS  ACTION  RESPONSABILITIES
"THE MANUFACTURER" :
 He is the builder of a part of the "MACHINE"
He supplies the material which complies with the standard CE. The material is delivered with the marking CE and all necessary documents, among the certificate CE and the assembly instructions and of use of the material written in the customer's language.
 "THE INSTALLER" :
He sets up and brings into service the "MACHINE"
Even if he is not the supplier of the material, he has the responsability of the assembly and of the save operation of the "MACHINE".
His obligation is, at least, for example in the case of the installation of a motorization of an existing gate :
- To check that the different elements of the new motorization have all a marking and a certificate CE.
- Respect the assembly instructions supplied by the manufacturer.
- After the adjustement of the "MACHINE", he tests the operating of the machine with a control unit certified.
- To train the user to the manoeuvre and hands the instructions over to him and the maintenance book of the "MACHINE" .

"THE INSTALLER" has an obligation of giving advice :
He has to propose a maintenance contract of the installation, that his customer has either to accept, or to refuse "officially", with a document signed by himself, relieving "THE INSTALLER" of his responsability.
 "THE USER" :
 He is the person who will use the "MACHINE" Warning: the customer is not always the "USER"
He has to respect the instruction manual. At least each 6 months, he has to organise the security maintenance of his installation.
The "MACHINE" :  A closing mechanism motorized or not (the door, the gate + the motorization + the order and security system), is considered as a "MACHINE" which has to respect the standard according to different criteria.
Among them, one of the most important is the
"TYPE OF USE"
defined according to 2 criteria :
"THE ZONE" and "THE USER" *
Note : a non functional door (which has not movement) is not a "MACHINE".
* According to our interpretation of the standard, which does not take into account the exceptions and particular cases.

3. Different levels of responsability for the "INSTALLER"
Example : installation of a new door of garage and its motorization.

1. CASE.
The door has a quality-label CE.
The motorization has a declaration CE.
A declaration EXISTS CE
which confirms that this combination of door and motorization has been tested, and that the "MACHINE" is normally formed CE.
"THE INSTALLER" installs, WITHOUT MODIFICATION, the material following the instructions for the assembly supplied by the "MANUFACTURER (S)",by reducing most of the risks by means of some compliant stickers.These stickers indicate the (minimal) risks that cannot be eliminated.

"THE INSTALLER" makes tests of the operating of the machine with a certified unit control, signs the certificate of conformity CE and hands the documents "USER" over to the customer.

 The customer signs a declaration that he was trained to operating machine, and that he has been informed about the obligation to organise a security control of the "MACHINE" each 6 months.
IN THIS FIRST CASE, "THE INSTALLER" is responsible for the assembly the machine.
 
2. CASE.
The door has a quality-label CE.
The motorization has a declaration CE.
IT DOES NOT EXIST any declaration CE
which confirms that this combination of door and motorization has been tested.
"THE INSTALLER" installs the material, following the assembly instructions supplied by the "MANUFACTURER(S)", by reducing most of the risks by means of some compliant stickers. These stickers indicate the (minimal) risks that cannot be eliminated.

"THE INSTALLER" tests the operating of the machine with a certified unit control, signs the certicate of conformity of the "MACHINE" CE and hands the documents "USER" over to the customer.

"THE INSTALLER" writes out a certificate conformity CE of this new "MACHINE".

 The customer signs a declaration that he was trained to operating machine, and that he has been informed about the obligation of organising a security control of the "MACHINE" each 6 months.
IN THIS SECOND CASE, "THE INSTALLER" is responsible to execute a TEST of conformity CE for the COMBINATION DOOR-MOTORIZATION and for the ASSEMBLY of the "MACHINE"
 
3. CASE.
The door is a serial production and does not have any quality-label CE .
The motorization has a declaration CE.
IT DOES NOT EXIST ANY declaration CE
which confirms that this combination of door and motorization was tested.
"THE INSTALLER" evaluates the risks and justifies all additional risks of the functioning.

"THE INSTALLER" installs the material, by reducing most of the risks and signals by means of compliant stickers. These stickers indicate the (minimal) risks that cannot be eliminated.

"THE INSTALLER" writes out a certificate of conformity CE of the new "MACHINE" (combination door + motorization) and puts a sticker on CE the installation.

"THE INSTALLER" makes tests of the operating of the machine with a certified unit control and hands the documents "USER" over to the customer.

 The customer signs a declaration that he was trained to operating machine, and that he has been informed about the obligation of organising a security control of the "MACHINE" each 6 months.
IN THIS THIRD CASE, "THE INSTALLER" is responsible to execute a TEST of conformity CE for the COMBINATION DOOR-MOTORIZATION and of the ASSEMBLY of the "MACHINE"

4. CASE. Singular production.
Possible Evolution of the Standard : here
The door is a singular production and does not have any quality-label CE .
The motorization has a declaration CE.
For these non standard products, IT DOES NOT EXIST ANY declaration CE
which confirms that this combination of door and of motorization was tested.
INFORMATION UNDER RESERVE

The singular production or custom-built, does not have any obligation of declaration and of marking CE . Possible development of the standard : here"THE INSTALLER" evaluates the risks) and justifies the additional risks for the functioning of "THE MACHINE"."THE INSTALLER" installs the material, by reducing most of risks by means of compliant stickers, the places where the (minimal) risks cannot be eliminated."THE INSTALLER" makes tests of the operating of the machine with a certified control unit and hands the documents "USER" over to the customer.

"THE INSTALLER" writes out a certificate of conformity CE of this new "MACHINE".

 The customer signs a declaration that he was trained to operating machine, and that he has been informed about the obligation of organising a security control of the "MACHINE" each 6 months.
IN THIS FOURTH CASE, "THE INSTALLER" is responsible to execute a TEST of conformity CE for the COMBINATION DOOR-MOTORIZATION and the ASSEMBLY of the "MACHINE"

4. "THE INSTALLER" has some new obligations :

- The installed material must be controlled.
- The customer has to be informed about the use and the maintenance of his installation, twice a year.
- The obligation to write out 2 files for every "MACHINE":
The technical file of the "MACHINE"
The installor has to keep this file for 10 years
The documents for the "USER"
These documents are essentially composed of the maintenance bookt
This file is composed of documents used for the assembly of the "MACHINE" :
- The anlysis and the method to keep the risks away.
- The mechanical project.
- The electric project.
- Check of conformity.
- The marking CE of the "MACHINE".		 These documents are composed of :
 
- the maintenance book of the "MACHINE".
- The instructions of use and maintenance of the "MACHINE".
- The certificate CE of the "MACHINE".
- All documents and all types of warning.