vertical fire curtain · cable gland drill a 20 mm diameter hole in a suitable location close to...

Coopers Fire Ltd, Edward House, Penner Road, Havant, Hampshire, PO9 1QZ, UK | Registered in England Number: 2010274Phone: +44(0) 23 9245 4405 | Fax: +44(0) 23 9249 2732 | Email: [email protected] | Web: www.coopersfire.com

Issue: 2 Revision 1

Vertical Fire CurtainInstallation Manual

02/2011

FireMaster™ | FireMaster™ Plus

VarioSpeed™ 6

PSU BBU CAM(Power Supply Unit, Battery Back Up Controls at Motor)

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© This manual is the exclusive property of A Cooper Group of Companies Limited, is copyright protected and strictly confidential. It must not be copied or reproduced in any form without written consent from Coopers Fire Ltd.

Coopers Fire policy is one of continual development and we reserve the right to modify, add or delete specifications and/or products without prior notice.

Service Contact:

Plug In Un-Plug/ Isolate Attention

Guide/Key

PAGE: 2 © Coopers Fire Ltd.

www.coopersfire.com

[email protected]

+44 (0) 23 9245 4405

+44 (0) 23 9249 2732

UK:

www.coopersfire.com.au

[email protected]

+61 (0) 2 9526 5190

+61 (0) 2 9526 5876

AUS:

Distributor InformationCompany:Address:

Telephone:Fax:Email:Contact:Website:

®Country

Post Code:

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PAGE: 3© Coopers Fire Ltd.

Contents

1.0 Mechanical Installation. 31.1 Head box and fixing options. 41.2 Roller Installation. 71.3 Stall Brackets and Catch Brackets. 91.4 Side guide fixing options. 101.5 Adjustment Channel and Side channel installation. 111.6 Bottom Bar and Retainer. 131.7 Side guide retainers. 181.8 Head box cover plates. 192.0 Electrical installation procedure. 202.1 Setting up the Motor Control Unit. 222.2 Initial Power and Test. 242.3 PSU Checks. 27

Disclaimer:

This installation guide is for a Coopers Fire Ltd, Fire Curtain only. However in certain circumstances/applications will cover smoke curtains inclusive of side channels. This manual should only be used by competent installers with relevant training and experience, if in doubt Coopers Fire advise you to contact your distributor.

1.0 Mechanical Installation.Mechanical installation procedure (the fire curtain head box is delivered in kit form) for single or multiple rollers.

- Verification of the fire barrier line and head box installation location is to be ascertained using the drawings provided by Coopers Fire which are approved by the customer, or their representative. - It is imperative that the fire barrier is not situated close to any obstruction that may impede the operation. - Check all the materials before the start of the installation.

MECHANICAL ELECTRICALHead Box and FixingsRollers and CurtainStall Brackets, catch bracketsAdjustment/Side ChannelsBottom Bar and RetainerHeadbox Cover Plates

Electrical InstallationSetting up the Motor Control UnitInitial Power and TestPSU Checks

The installation is broken down into the following sections:

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Face Fixed Top Fixed

Unistrut/ Rod Fixed I Beam Fixed


For fixing and drilling technical information please see page 5.

1000mmMax Appropriate

Fire Barrier

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A minimum fixing size of M10 must be used to achieve an approved Coopers Fire, Fire Curtain installation. At least 2 x M10 fixings must be installed at a pitch of 1000mm along the full length of the head box and embedded into the fixing interface a minimum depth of 60mm. A minimum fixing size of M8 must be used to achieve an approved Coopers Fire, Smoke Curtain installation. Refer to installation manual for more information.

M10 X 40Wedge Anchor

M10 RawlockBolt Projecting

M10Coach Screw

M10Ankascrew

HeadboxApproved fixings for Fire Curtains

A minimum fixing size of M6 must be used to achieve an approved Coopers Fire Side Channel installation. Each pre-drilled fixing hole along the full length of the Adjustment Channel and Angle Channel (if applicable) Must be utilised. Fixings must be embedded at least 60mm into the interface.

Side Guides

M6Ankascrew

M6 RawlockBolt Projecting

M6Coach Screw

Drilling Information

Headbox

Side Guides

Fixing type Anchor Length Minimum Embedment Depth

Hole Diameter Hole Depth Edge Distance

M10 X 40 wedge Anchor

40 60 12 42 120

M10 Rawlock Bolt Projecting

70 60 12 65 (min) 70

M10 Coach Screw

70 60 N/A N/A 70

M10 Ankascrew 70 60 8 75 50

Fixing type Anchor Length Minimum Embedment Depth

Hole Diameter Hole Depth Edge Distance

M6 Coach Screw

70 60 N/A N/A 70

M6 Rawlock Bolt Projecting

70 60 5 65 (min) 70

M6 Ankascrew 70 60 5 75 50

Coopers Fire Ltd information on drilling and drilling depths for approved fixings. Incorrect fitting could lead to impeded performance of the curtain.


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Hanger distances to be mounted on the box are shown in the picture below

M10 Threaded Rod

Nut

Spring Washer

Square Washer

Uni Strut

It is critical when using UNISTRUT fixings to have the correct component order to ensure a solid fixing .The threaded rod should have; a square washer, a spring washer and a full nut on each side of the fixing.

NB, 1000 mm is the maximum permissible distance between centres of headbox fixings.

Hangers should be located at a minimum of 100mm from the end of the headbox.

Use 4.8x 11mm rivets.

IMPORTANT: Horizontal levelling of the fire head box and rollers is critical. Any deviation from this may damage the performance of the fire curtain.

MAX. 100MM

Threaded (M10 steel) rod/hangers must be a maximum of 1000mm in length.

The headbox joiner has pre-drilled holes that will align with the fixing holes on the headbox. Use either 4.8x11mm rivets or M5x12mm bolts with nyloc nuts to join the headbox.

MAX. 1000MM C/C'S

MAX. 1000MM C/C'S

MAX. 100MM

MAX. 1000MM


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1.2 Roller Installation.

Extend the tail bearing out as far as it will go. Lift the roller up resting the bearing into the tail bearing bracket first, then slide the roller back inserting the motor end in to the motor bracket and insert the fixing clip.

Tail end bearing

20mm dia hole

Motor Bracket

Cable Gland

Drill a 20 mm diameter hole in a suitable location close to the motor bracket for the motor cable, and install a cable gland to make sure that the cable will not become damaged.

Measure the length of the roller, with tail pins retracted, check the corresponding size where the roller is to be installed within the headbox.

Inside Outside

1.

2.

Slide bearing out

Mount bearing into the tail end bracket and slide the extended portion of the roller back to its original position

3.

Slide the roller toward the motor end bracket and secure with a motor clip.Tail Bearing

split pin

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Motor Clip

Check the roller is inserted properly by giving the roller a shake and double check the roller does not pull out of the bracket at the motor end.

Install cable tie to secure the motor cable away from the fabric as illustrated.


Motor Bracket

Feed the motor cable though the cable gland, which is fitted in the 20mm hole in the head box and secure with a heavy duty preferably steel cable tie.

NB. Motor cable is supplied with standard cable for standard fire curtain and FP200 fire protected cable for Emergency Retract Units.

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1.3 Stall Brackets and Catch Brackets.

Ensure that the stall brackets (supplied), are installed onto the stall brackets located at the end of the head boxing. This is a crucial part of the installation.

41mmStall bracket

Bracket fitting

Ensure that the catch bracket has been installed at each required location using the M6x12 bolts provided.

M6X12 Bolt

Catch Bracket Assembly.


Stall Brackets

NB. If the stall brackets are not installed, the bottom bar may pull into the head boxing, resulting in a failure.

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1.4 Side guide fixing options.

100 (MAX)

33

4090 (MIN)

29Adjustment Channel

Side Guide.

3.9x11mm SDST Screw.

For approved fixing & drilling requirements see: Page 5.

Angle Channel

Standard straight fitting.

NB. If the side channel is mounting into the wall it is important to ensure that a 5mm gap is left around the side jaws.

5mm

5mm

Recess Wall fitting

45mm

40mm

3mm


Mounted side guide.Reverse mounted side guide. Angle Channel Dimensions

X

Model XFireMaster™ 5mmFireMaster™ Plus 8mm

To achieve a mounted or a reverse mounted fitting it may be necessary to attach the front facing section whilst the angle channel and adjustment channel are attached to the desired surface. Then once this fixing has been made, remove the entire assembly and fix the inner section of the side guide assembly to the adjustment channel. This is then re mounted onto the wall and aligned to be plumb.

Angle Channel

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x = Adjustment chanel length

Finished Floor Level (FFL)

ceiling

NB. A minimum fixing size of M6 must be used to achieve an approved Coopers Fire, Side Channel installation. Each pre-drilled fixing hole along the full length of the Adjustment Channel and Angle Channel (if applicable) Must be utilised. Fixings must be embedded at least 60mm into the interface. (Refer to section 1.1 for approved fixing methods)

Headbox

The Side Guide Adjustment Channels should be fitted from the underside of the head boxing to the Finished Floor Level (FFL). The size is dependant on the drop from the bottom of the head boxing to Finished Floor Level (FFL). Ensure that the fixings are at the top of each slot, so that in case of fire it will allow the channels to expand upwards. All fixing holes should be used. (Refer to section 1.1 for approved fixing methods).


1.5 Adjustment Channel and Side channel installation.

It is important at this point to check the centre line of the adjustment channel is 42mm from the face of the headbox.

For FireMaster™ Plus Single roller this value is 59mm.

42mm

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Measure and cut the side channels to the correct length, nominal 70mm inside the boxing and fit to the adjustment channels, but do not secure at this time. The fire barrier line should be in a straight line from the centre of the channel to the mid point of the fabric build up as a start point.

The side guide channels must be installed at 90° to the head boxing and parallel to each other.

Once adjustment channels are positioned correctly the guides can be secured to the channels with 3.9x11 mm self drill self tapping steel screws (SDST) at 300mm pitch. Ensure the poppers in the fire barrier do not snag on the side guide channels and allow as much room as possible so that the poppers run freely within the guide.

It is important when fitting the SDST screws that they are fixed at the furthest possible point back into the side channel as to prevent the bottom bar retainers from snagging on the fixings.

70m

m

Headbox

90-100mmS

ide-

Gui

de

It is essential that the side channels are installed ‘plumb’. 70

100

300

300

90° 90°

Headbox

Side guide length = adjustment channel length + 70mm


90°

Finished Floor Level

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Install a 100x100 steel adaptable box near to the motor locations on the headbox. Carefully and neatly route the motor cable through the headbox cable gland and into the 100 x 100 adaptable box, via a second cable gland as illustrated.

1.6 Bottom Bar and Retainer.

Motor Cable(direct from motor)

Motor Cable Extension, use 3 core Low Smoke & Fume cable (not twin and earth) or FP 200 cable.

100 x 100 Steel Adaptable box

Before Installing the bottom bar the motor needs to be connected to its corresponding Motor Control Unit (MCU).

Maximum Distance Maximum DistanceCable Size 11Nm Motor (White) 30Nm Motor (Red)

1.5 mm2 35m 25m2.5mm2 58m 42m4.0mm2 93m 67m6.0mm2 139m 100m

Refer to the table below for motor cable extension guidelines.

NB. This is a guideline only and does not consider correction factors for specific site conditions.

230Vac


(to Motor Control Unit)

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1

2

3

1

2

3

1

2

3

1

2

3

Join the motor cables to the motor extension cable in a 3 way piece of 15 Amp terminal block as shown below.

The rotation of the curtain needs to be acquired and wired accordingly (Note: the inner core cables are number):

= Clockwise during descent

= Anti Clockwise during descent

M

M

(Looking from ‘motor end’)

(Looking from ‘motor end’)

Before this procedure is started you must connect the motor cable to the Motor Control Card, and the Motor Control Card to the power supply unit. See section 2.0

Clockwise:

Anti-clockwise:

Lower the curtain(s); they can be pulled down by hand. Each curtain will need to be pulled down individually. Ensure they are fully deployed at this point double check the curtain measurements and that each roller is fully turned to the half past position.


Motor

Motor

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Using a chalk line mark off the exact drop length of the curtain indicated on the customer drawings. Make another chalk line above the first chalk line; this will identify the top edge of the bottom bar. Cut each curtain along the bottom chalk line, raise each curtain up to working height using the ‘Manual’ control function on the Motor Control Card (MCC).

1 2

The bottom bar is in two parts, inner and outer. Cut one length of inner bottom bar in half.

Ensure that all curtains are hanging ‘plumb’, this is crucial before installing the bottom bar. The headboxing/ rollers may not be square/level if the curtains do not hang plumb.


Type of B/B Size (mm)Fire Normal 60Fire Jumbo 70

3

2.5 M

Cut the inner section in half only!

1.25

M

x2

One

inne

r sec

tion

Cut in half

Inner

Outer

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Fit a full length outer bar to the reverse side of the curtain. Use a 5mm drill bit to make holes in the curtain for the fixing bolts, drill through the pre-drilled holes in the bottom bar.

The bottom bar must be level across the entire length of the curtain.

Bottom Bar

Apply the double sided tape to the pre cut 1.25m inner section of bottom bar. Using the second chalk line align the top of the bottom bar to the chalk line and press firmly into place, the tape will hold it in place until final fixing is made.

The start position of the bottom bar must be 25mm from the side channel.

25mm


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The bottom bar needs to be staggered on final fitting to ensure a solid and structurally sound assembly.

Full InnerHalf Inner

Full Outer

Cut to length Inner

Cut to length Outer

Full Inner

Full Outer Full Outer

Curtain

Bottom Bar-Inner

Bottom Bar-Outer

Weight Bar

Fixing Bolt 5x12mmFixing nut Nyloc

NB: A weight bar of up to 6 kg per linear metre is allowable, but as a general rule the optimum weight is the minimum that allows the fire barrier to achieve gravity fail safe if in doubt check the fire engineers requirement.

The minimum weights required to GFS a Fire Curtain are displayed below note these weights are minimum and Per Motor:

Fix the bottom bar using 5x12mm bolts and 5mm nyloc nuts. Face the head of the bolt towards the best way cosmetically.

25mm x 5mm 0.966 kg per linear metre12mm x 12mm 1.13 kg per linear metreJumbo Bottom Bar 3.50 kg per linear metre

Bottom Bar Weights


Motor Minimum Weight per Motor 11Nm (White) 7Kg30Nm( Red) 13Kg

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1 2

CLICK

Steel Press StudsM

ale

Fem

ale

N.B. The press studs need to be crimped firmly together for a secure fit.

25mm

Bottom Bar

Side

Cha

nnel

5mm


3

Once side guide retainers are fitted using manual control button, send the curtain up to the top where the side retainers are then lifted into the mouth of the side guide each end of the curtain, then return the curtain to the down position to check the running of the retainers in the side guides.

Now the bottom bar is installed the side guide retainers can be fitted an mounted into the side guides.

1.7 Side guide retainers.

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Install the bottom cover plates, starting at one end with 3.9x11mm pan pozi screws.

NB. Side guides removed for clarity

A cover plate connector is to be fitted, where the covers join and is installed by simply pushing the connector equally over the join.

41mm

Once the headbox is fully assembled ensure the opening in the headbox (where the bottom bar finishes) is set to 41mm.

Install the front cover plates, starting at one end with 3.9x11mm pan pozi screws.


1.8 Head box cover plates.Before fitting the cover plates, ensure the motor cable is not interfering with the rotation of the roller by securing the cable to the extended motor drive shaft with a cable tie.

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Install the PSU at the location provided on site. This should usually be an electrical riser within the building. The PSU BBU CAM has 3 main connections into the enclosure (See Below). Signal is removed upon receipt of an alarm signal from the building’s main fire alarm system. This allows the curtain to drop to the down position under controlled descent (Gravity Fail Safe).

230Vac

A1. 230Vac 50Hz Dedicated supply via 13A non-switched fused spur

2. 24 Vdc from PSU to alarm and back via Normally closed volt free contacts (others).

3. 24Vdc out to motor control units. See table below.

Warning!230Vac

2x12v 12A/HInternal batteries.

24Vdc

MCU

Cable Size 1.5mm2 2.5mm2 4mm2 6mm2

Number of MCU Current (A) Radial Ring Radial Ring Radial Ring Radial Ring1 0.3 290 NA 483 NA 775 NA 1161 NA

5 1.5 58 116 96 192 155 310 232 464

10 3.0 29 58 38 96 77 154 116 232

15 4.5 19 28 32 64 51 102 77 154

20 6.0 14 28 24 48 38 76 58 116

2.0 Electrical installation procedure.BBU-CAM (Battery Backup Controls at Motor)

PAGE: 20 © Coopers Fire ltd.

Table showing size of cable against Radial and Ring wiring configurations, these are maximum calculated distances. In Metres.

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LN - - - - - - S S

Connect the Motor Control Unit as illustrated above.

OFF

ON

SW4

RUN

IN

STAL

L

SW1

Man

ual

Soft

Set

SW2S

W3

ON

ON

LKSW2

LKSW3

PL1

1 32

LK2

1 2

GRA

VITY

SPE

ED

+VE

-VE

CN4

1345 2

0VSIG CN3

13 2

CN2

13 21

3 2

CWACW

CN1

Mot

or

Transformer

Motor Control Card

(MCC)

M

From PSU BBU CAM

Out to next MCU

Out to next MCU

To motor in fire curtain.

LEN

Slave Line

112

2

cwacw

3 3

A MCU’S

++ + + + +

NL

- +

+-+-


Connect the PSU BBU CAM as illustrated above.

(If Conjoined)

230 Vac 50Hz dedicated supply Via 13A non switched fused spur

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OFFO N

SW4

RUN INSTALL

SW1

Manual Soft Set

SW2S W3

ON ONLKSW

2

LKSW

3

PL1

1

3

2

LK2 1

2

GRAVITY SPEED

+VE

-VE

CN4

1

3

4

5

2

0V

SIG

CN3

1

3

2

CN2

1

3

21

3

2

CW ACW

CN1

Motor

Table 1 Switch positions

LKSW2 LKSW3 Stall CurrentOff Off 1.2AOn Off 2.2AOff On 3.2AOn On 4.2A

Ensure that switches LKSW2+LKSW3 are both set to the OFF position (away from the edge of the PCB) position. This is the lowest stall current setting point and is 1.2 Amps. If the current on the motor exceeds this value then the motor will stop and the brake will be applied. If the motor stops unexpectedly it may be that the stall current needs changing to a higher value. The current settings for each combination of switch positions are shown in Table 1.

ON ON

LKSW

2

LKSW

3

ON

ON

LKSW

2

LKSW

3

ON

ON

LKSW

2

LKSW

3

ON ONLK

SW2

LKSW

3

1.2A 2.2A

3.2A 4.2A

2.1 Setting up the Motor Control Unit.

On each MCU ensure that the INSTALL / RUN switch is in the INSTALL position. LD1 will be lit.


LD1

Motor Control Card(MCC)

Caution: correct polarity must be used on all DC connections and that there are no short-circuits on external wiring.

LD1 LD2 LD3

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Locate the preset potentiometer VR1 on each Motor Control Unit and set it to the half-way position. This preset controls the descent speed of the curtains and it is best that they are all set the same. It is critical that they are set the same in a conjoined system. This control may need fine adjustment during testing.

GRAVITY SPEED

-+

GRAVITY SPEED

NB. The preset may not be set to the middle position upon delivery.

Increase Decrease

Figure 3 configuration:

Ensure that the jumper settings PL1 & LK2 are set as shown below

Ensure that SW4 is set to ‘OFF’ as illustrated above.

VR1


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With the Key-switch in the TEST position: Apply power to the PSU BBU CAM and the curtain MCU’s. Connect the batteries (provided) at this point observing correct polarity. Note that the batteries provide 24Vdc and should be wired in series.

Each control panel has a key-switch and reset push-button that allows simple testing of the fire or smoke barrier system.

RESET

2.2 Initial Power and Test.

Monitor the curtains controlled by the PSU closely during this following stage: Turn the key-switch to the NORMAL position then press the RESET push-button. The curtains should start to rise together. If they do not then immediately return the key-switch to the TEST position and let the curtains drop to the floor again. Determine why the motors did not operate together and correct the fault BEFORE re-testing the system. Allowing a conjoined curtain to rise too far with one or more motors failing can damage the system.

Test

Power

Alarm Active

Alarm Off

Normal

Reset

LED ON/OFF RESULT

PowerON Power OnOFF Power Off

Alarm ActiveON Alarm circuit Healthy &

PSU BBU CAM RESETOFF Alarm Circuit Off

Alarm OffON Alarm Circuit Activated

FLASHING Alarm Circuit Healthy, PSU BBU CAM not yet Reset.

Check that LD1 is permanently illuminated on ALL MCU’s, if flashing, switch SW1 to install.

Ensure all curtains are rising in the correct rotational direction.

If any curtain back drives & begins to raise in the incorrect rotational direction, immediately remove power & check the motor connections 1,2 and 3.

Normal

Test

Normal

Test


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Soft Set

Set a marker 300mm below the headbox, when the bottom bar aligns with the set mark, press the ‘soft set’ button (SW3) on any one of the MCU’s operating the fire curtain.

Check that LD2 illuminates on all MCC’s once the ‘soft set’ button has been pressed. This indicates that all MCC’s have received the ‘soft set’ command through the slave line.

Check/observe that the fire curtain ascent speed slows by approximately 50% once the ‘soft set’ has been activated.

The curtain will continue to drive until the bottom bar locates inside the headbox.

The MCC’s will detect when the bottom bar has located in the headbox by monitoring the current drawn by the motor(s). When the bottom bar locates inside the headbox, the motor current rises and the brake will apply when the motor current exceeds the ‘set value’ by the SW2+SW3 combination.


Check that LD3 is illuminated on the MCC’s when the bottom bar has stalled. This indicates that the brake has been applied.

Bottom Bar

SW3

Bottom Bar


300mm

LD2

LD3


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Switch all MCC’s to run mode after the soft set has been correctly set and the bottom bar has correctly located in the headbox.

Check that LD1 begins to flash on all MCC’s (1 pulse per second) when SW1 has been switched to run.

The ‘soft set’ position will now remain in the internal memory of the MCC.Test the curtain using the test switch facility as described in section 2.2.

Check that the curtain automatically switches into ‘soft set’ mode where previously programmed

Check the bottom bar locates correctly into the headbox and that LD3 illuminates.

Test the curtain 5 times and ensure that it runs correctly. Leave a 4 minute cooling period for every 1 minute of operation.

LD3

LD1


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2.3 PSU Checks.

LD1 ON - LD2 OFFFLASHING - LD2 OFFFLASHING - LD2 ON

Alarm Circuit OFFAlarm On, PSU alarm resetSlave line from other PSU.

LD3 ONOFF

12V supply OFF12 supply OFF

LD4 ONOFF

5V supply ON5V supply OFF

LD5 FLASHINGONOFF

Battery is ChargingBattery ChargedBattery Low, Disconnected or Faulty

LKSW1 ON Battery Back-up Buzzer MutedLKSW1 OFF Battery Back-up Buzzer NormalVR1 BB Battery Back up Buzzer Potenitiometer/timer (3-60min)

LED Indicators

Switch Positions

ON

LD1

LD2

LD3

LD4

LD5

EXPANSION

LKSW1

VR1

1A

10A

PZU

SLA

VE

ALARMLOCAL

COM.

NO

.

NC

.

TO C

ON

TRO

LS

1A

L N E

MAINS

FUSE

FUSE

FUSE

AUX OUTPUT12V24V

SLV

0V

S

S

0V BUT K/S

Power Zone Unit & Charger(PZUC)

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Coopers Fire Ltd, Edward House, Penner Road, Havant, Hampshire PO9 1QZ UK | Registered in England Number: 2010274

Phone: +44(0) 23 9245 4405 | Fax: +44(0) 23 9249 2732 | Email: [email protected] | Web: www.coopersfire.com

vertical fire curtain · cable gland drill a 20 mm diameter hole in a suitable location close to...

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