GEZE Powerdrive Pre-Mounting & Safety Test Guide

5.8 Connecting motor gear unit and control unit

Powerdrive PL

• Lay the rotary encoder cable (2) and motor connection cable (3) to the control unit.
• Insert the connector into the control unit (4).

Powerdrive PL-FR

• Route the rotary encoder cable (2), motor connection cable (3) and motor connection cable of the second motor gear unit (1) to control unit.
• Insert the connector into the control unit (4).

5.9 Connecting the tooth belt locking mechanism (optional) and control unit

• Plug the cable for tooth belt locking mechanism (1) in at the control unit (2).
• Lay the cable for tooth belt locking mechanism (1) through the cable guide to the tooth belt locking mechanism (optional) (3), shorten if necessary, strip and attach the insulated wire-end ferrules.
• Connect the tooth belt locking mechanism (option) as shown on the wiring diagram.

5.10 Fitting the transformer ground

• Connect the earthing cable (1) from the transformer to the device flat plug (2).

The track is not earthed if there is a poor connection between earthing jumper (3) and track.

• Check whether the setscrews (4) of the earthing jumper (3) penetrate the anodised layer of the track.

5.11 Fitting the cover earthing

• Screw the cable shoe of the cover earthing cable (6) using a countersunk screw (3), serrated washer (4) and hexagon nut (5) to the cover (7).
• Connect the earthing cable (2) of the cover with the second plug-in connection of the device flat plug (1).
• Keep the counterbore (8) clear of any coatings.
• Remove the coating at some points in the dotted area (9) on the inside of the cover, if there are no blank points available for the device safety test.

5.12 Installing the side plates

• Screw the side plates (2) to side of the track with 4.8 x 13 countersunk tapping screws (1).
• Screw the retaining block (4) to the side plates (2) on the inside with 4.8 x 13 countersunk tapping screws (3).
• Screw the threaded pins (5) completely into the retaining blocks (4) from below.
• Glue the side cover panels (7) to the side plates (2) on the outside with 4 glue dots (6) each.
• When gluing, note the following:
  • The glued surfaces must be clean and grease-free.
  • The visible surfaces of the side cover panels must be on the outside.
  • The top edges of the side plates and the side cover panel must be flush.

5.13 Connecting the rechargeable battery and control unit

• Do not reach into the area of moving parts.
• Check whether the rechargeable battery cable (1) is long enough.
• If necessary, plug the rechargeable battery extension cable to the rechargeable battery cable.
• Route the rechargeable battery cable (1) to the control unit.
• Insert the connector into the control unit.

6. Device safety test and production test

• The electrical system (230 V/115 V) may only be connected and disconnected by a professional electrician or specialist electrical technician.
• Complete a device safety test according to EN 60335-1 Annex A.

The device safety test consists of the following parts:

• Protective earth test with 10A test current
• Insulation strength testing (high voltage test) with 1000 VAC

A testing device suitable for this standard must be used.

Testing process

• Connect the mains cable with the mains plug to the transformer.
• Insert the mains plug in the testing device.
• Start the test on the testing device.
• Use the probe to test all metal parts connected to the protective conductor in sequence. The low ohm connection between the PE line of the mains cable and the metal part contacted with the probe is tested in each case.

Use the probe to contact at least the following test points:

• Transformer metal bracket
• PE connection on the secondary side of the transformer (luster terminal)
• Track (blank, non-anodised area)
• Device flat plug for transformer ground connection
• Cover (blank, non-anodised area)

All protective earth connections must have a resistance of less than 0.1 Ω.

• Then start an insulation strength test (high voltage test) on the testing device.

Only drives that have passed the device safety test may be operated. The results of the device safety test must be documented in a traceable manner along with the serial number of the drive.

After the device safety test, do not remove the device flat plug of the ground connection from the track.

• Complete the production test as described in the wiring diagram.

6.1 Unplugging the cables

• Unplug the rechargeable battery cable from the control unit and secure it for transport.
• Unplug the ground line on the cover from the ground connector.