DORMA ES 90/100 Commissioning & Adjustment Manual

1. Preparations for Commissioning

1.1 Basic Prerequisites

• The operator has been completely installed.
• The protective earth conductor is connected.
• The back-up storage battery module is plugged in.
• The light barriers are connected.
• The expansion module is plugged in.
• The separately supplied components such as program switch, activators and lock systems have been installed and connected.
• The end stops are adjusted so that at the maximum opening width both (outer) sliding panels come into contact with the stops, and the sliding panels and stationary screens do not collide at their respective sealing profiles when the door is closed.

2. Commissioning

1. Move the door panels to the half-open position.
2. Set the program switch to "OFF".
3. Unlatch the emergency stop switch.
4. Press the service pushbutton while at the same time switching on the mains power.
5. Wait approx. 20 seconds for the switch-on phase to be completed and for the control unit to carry out a self-test. The operational status display LED lights up and the door should now slowly close.

The door performs a closing cycle.

6. Once it has reached the closed position, set the program switch to "AUTOMATIC".
7. Depress the service pushbutton for approx. 3 seconds.

The door set now performs a learning cycle:

• The door opens at creep speed to determine the opening width. Once the door is in the open position, press the panels against the end stops to enable the system to identify the motor type.
• Opening width and motor type are then stored.
• The door set then tests whether a lock is connected and if so, what type of lock.
• For this purpose, the door opens and closes a short distance up to three times.

8. Briefly depress the service pushbutton.

The door opens quickly, the control unit stores the door parameters and then performs a back-up battery test.

Note: When using the ES concealed rod multipoint lock, perform the procedures specified under step 8 overleaf: Concealed rod multipoint lock.

3. Settings

3.1 Expansion module 4 (EM4)

The control unit is preset so that it is optimised for the most common applications.

• By resetting a jumper, the emergency open function can be converted into an emergency close function. For this, unscrew and remove the housing cover of the module.
• If another setting should be required, this must be implemented using the hand terminal (HT). (See hand terminal operating instructions).

3.2 Re-instating the default settings

1. Depress the service button while at the same time switching on the mains power. The door performs a closing cycle.
2. Once the closed position has been reached, release the service pushbutton and set the program switch to "AUTOMATIC".

The door performs a learning cycle and then switches all parameters to the default settings.

3.3 Setting the partial opening width

The partial opening width can be set using the program switch in accordance with individual requirements.

1. Set the program switch to "PERMANENT OPEN". Door opens at creep speed.
2. Once the required partial opening width has been reached, set the program switch to "PARTIAL OPENING".

The door stops and the newly set partial opening width is stored.

Note: The program switch function for setting the partial opening width can be disenabled using the hand terminal. The partial opening width can then only be set and adjusted using the hand terminal.

4. Functional Testing

4.1 Light barriers

1. Interrupt the light barriers individually during the closing cycle. The corresponding LED on the expansion module lights up and the door reverses.
2. With the door open, interrupt the light barriers for a period of several seconds. The door should remain open as long as the light barrier transmission paths are interrupted.

Once the obstruction of the light barriers has been removed, the door should close on expiry of the preset hold-open time.

An automatic test of the light barriers is additionally performed prior to each closing cycle.

4.2 Activators

Test all connected activators in the various program switch settings. Perform settings and adjustments for the activators in accordance with the corresponding installation instructions.

4.3 Emergency opening - operation with back-up battery module

1. Set the program switch to "OFF" and remove mains plug. Lock should not disengage and door should not open.
2. Set program switch to "AUTOMATIC". Door should unlock and open.
3. Re-insert mains plug. Door should close at creep speed.
4. Leave program switch in "AUTOMATIC" setting and remove mains plug. Door should open.

4.4 Emergency stop - operation with backup battery module

1. Set program switch to "AUTOMATIC" and during the closing cycle, operate the emergency stop switch. Door should stop and reverse.

4.5 Lock

• Set program switch to "OFF": Door should be locked in closed condition.
• In all other program switch settings: Door should be unlocked.

The lock can be adapted with the hand terminal at the request of the customer. (See hand terminal operating instructions)

4.6 Night-bank activator

1. Set program switch to "OFF".
2. Issue an opening signal using the "NIGHT-BANK" activator. The door should unlock and open. The door should close and lock automatically once the user has passed through the door or, at the latest, on expiry of the pre-set "NIGHT-BANK hold-open time".
3. Remove mains plug.
4. Issue an opening signal using the "NIGHT.BANK" activator. Door should unlock and open as long as the NIGHT.BANK-signal remains live.

With the KT 8 key switch as the activator, the door can also be unlocked if the power is disconnected.

1. Push the door closed by hand.
2. Turn the key switch counter-clockwise. Door should lock.

5. Further Information (Diagnostics)

• The door system performs a self-test every 4 hours or at appropriate times after the system has been switched on.
• In this self-test, an emergency opening cycle is performed under battery power and the control unit is checked for integrity. If the self-test should fail, the door remains in the open position.
• The door can be closed by setting the program switch to "OFF".
• At the next opening signal, a further self-test is performed.

6. Optional Functions

If the functions described below have been implemented, they must be tested as follows.

6.1 Airlock (two doors in tandem)

• Depending on the side from which the opening signal is initiated, the first door in the access sequence should initially open and then close.
• Only after the first door has closed should the second door open and close.

6.2 Presence detector (bell contact)

Check the bell contact by interrupting the light barriers.

6.3 Door status monitor

Check the audible or visual door status detectors.

6.4 Panic/emergency closing

• The panic/emergency closing function must be set using the DIP switches and hand terminal.
• Initiate a NIGHT/BANK signal in each of the program switch modes "AUTOMATIC", "EXIT ONLY", "PARTIAL OPEN" and "PERMANENT OPEN". The door should close immediately.
• The door should not open either when the light barriers are interrupted or when a signal is issued by radar detectors.
• Cancelling the panic/emergency closing function: Set the program switch to "OFF", and then back to the required mode.

Then test all the other functions: Opening and reversing via the radar detector; Reversing via the light barriers.

7. Force Limitation

7.1 Adjusting the static force limits

According to the German standard ZH 1/494, sliding doors can be operated without hinged safety pocket screens to safeguard the nip points provided that the static forces are limited to values less than 150 N.

Guideline Parameters:

• ES 90/100 control unit with motor type GR 63x25:
  • Force limit CLOSE: 86% (max. force: 147N)
  • Force limit OPEN: 27% (max. force: 145N)
• ES 90/100 control unit with motor type GR 63x55:
  • Force limit CLOSE: 80% (max. force: 147N)
  • Force limit OPEN: 25%

Additional protection: As additional protection for the area safeguarded by the safety devices, a creep speed travel distance in the OPEN direction must be set for the door at 67% (approx. 20 cm).

The reduced force limit restricts the permissible motor current which in turn reduces acceleration and velocity.

7.2 Adjusting the dynamic force limit (as per prEN 12650)

The closing edges can also be protected by limiting the dynamic forces and a light barrier, preferably installed at a height of 0.5m.

Guide values:

• ES 90/100 control unit with motor type GR 63x25:
  • Opening speed: 57%
  • Creep speed CLOSE: 53%
  • Creep speed distance CLOSE: -100%
  • Force limit CLOSE: 85% (max. force: 149N)
• ES 90/100 control units with motor type GR 63x55:
  • Opening speed: 57%
  • Creep speed CLOSE: 53%
  • Creep speed distance CLOSE: 100%
  • Force limit CLOSE: 85%

After they have been set, the dynamic forces must be checked and corrected at the closing edges in accordance with the ranges specified in prEN 12650.

8. Concealed Rod Multipoint Lock

Technical Data

• Supply voltage: The 24V power supply is picked off from terminals 11 and 19 on the basic module. This power supply also enables emergency unlocking and emergency opening in the event of a power failure provided that the expansion module is fitted with a back-up storage battery.
• Power consumption: 29mA; locking and unlocking, approx. 50mA.
• Temperature range: -20°C to 60°C.

8.1 Prerequisites

• Control unit of the concealed rod multipoint lock is fitted.
• Cabling has been installed and connected in accordance with the wiring diagrams.
• ESU jumper has been inserted at input "ESU".
• Jumper is set at input "Concealed rod multipoint lock ON".

8.2 Commissioning

1. In the DOOR CLOSED position, set the lock type using the hand terminal (see menu 4 "Door types" in the submenu "Special system"). Select "Concealed rod multipoint lock". Note: This setting procedure must be repeated after each initialization operation. After the learning cycle, the setting is retained.
2. Initiate an opening signal. The setting is stored once the door reaches the OPEN position.
3. Set the program switch to "OFF". The concealed rod multipoint lock should engage. The red fault LED should flash. The buzzer should emit three signal tones.

4. Check the wiring and perform a directional test. Monitor the signals at the control unit of the concealed rod multipoint lock. After a locking signal has been emitted, the locking rod must move down and the bottom limit switch must be closed.
5. Set the program switch of the ES 90/100 control unit to "AUTOMATIC". The concealed rod multipoint lock should unlock. The red fault LED should flash once. The buzzer should emit a single signal tone.

8.3 Settings

Setting the motor trip current using the potentiometer on the control unit:

1. Turn the potentiometer counter-clockwise to its limit.
2. Engage and disengage the concealed rod multipoint lock several times while observing the green LED.
3. Gradually turn the potentiometer clockwise until the green LED briefly flashes. The current limit has now been reached.
4. Turn the potentiometer a further small degree clockwise until the LED is extinguished. This completes the setting operation.

Check the limit switches and adjust as appropriate: The switches must be firmly closed in their respective end positions and the rack should not yet have reached its mechanical limit.

DIP Switch Settings

• DIP switch 1 (Fault LED): ON = Fault indicator on; OFF = Fault indicator off.
• DIP switch 2 (Signal tone): ON = Audible signal on; OFF = Audible signal off.

8.4 Functional Tests

• Fault LED (red):
  • 1x flash: unlocking successfully completed.
  • 3x flashes: locking successfully completed.
  • Lights up: limit switches are open/closed in idle state.
  • Continuous light: signals fault.
• Buzzer:
  • 1x signal: unlocking successfully completed.
  • 3x signals: locking successfully completed.
  • Continuous signal: indicates fault (shutdown after 1 minute).
• Standby LED (green): Lights up when the motor overcurrent monitor responds.

Locking/Unlocking Logic: The STOP output disables the door operator during the locking and unlocking operation. If not completed within 2 seconds, a short audible alarm is emitted. The attempt is repeated twice. After a fault, the faulted direction is tested a second time.

Manual Unlocking: Operation of the manual unlocking mechanism interrupts the motor connection. Locking and unlocking can be performed manually.

Tamper Protection: The brown wire of the cable must be connected last to PIN 11 to avoid short circuits.

9. Familiarisation

Once the commissioning and functional tests have been performed on the door set, the operating instructions should be handed over to the client/user and they should be properly familiarised with both the documentation and the system.

10. Further Information (Rev. 8)

The ES 90/100 Revision 8 (Rev. 8) control unit is a further development of the old ES 90/100 control system. The commissioning procedure is the same for both control types.

Differences in Rev. 8 Control:

1. Larger EPROM: The EPROMs cannot be used in the pre-Rev. 8 control units.
2. Concealed rod multipoint lock: Can only be connected to Rev. 8 controls. The lock type must be programmed using the hand terminal.
3. Force limit value: Can be adjusted to a value below 150N and retrieved using the hand terminal.
4. CP90 program selector: Can also be connected.
5. Incremental encoder test: Can be switched off after connecting mains power.
6. Night-bank function: Applies in all "AUTOMATIC" programs.
7. Disable functions: Hand terminal can initiate various disable functions.
8. Short circuit recovery: Mains plug merely has to be disconnected for 2-3 seconds and then re-connected.
9. Expansion modules: Modules with Transil diodes on the soldered side cannot be plugged into Rev. 8 basic modules due to mechanical incompatibility.
10. Serial Numbers: For Rev. 8 basic modules (GM), there is only one consecutive manufacturing serial number.