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ELECTRO-PNEUMATIC IN-SWING BUS DOOR CONTROL MECHANISM

Installation Operation and Maintenance Manual

BUS DOOR SYSTEM



Table of Contents

1. Introduction ............................................................................................................. 3

1.1. Definitions .............................................................................................................. 4

2. Operation principal ................................................................................................. 4

3. Identification ........................................................................................................... 5

4. Installation procedure ............................................................................................. 5

5. Maintenance ......................................................................................................... 12

6. Characteristics parts ............................................................................................. 12

6.1. Cylinder Ø63/100 ................................................................................................. 12

6.2. Solenoid valve SVAJ214 (Coil Operated) ............................................................ 12

6.3. Pneumatic emergency valve ................................................................................ 13

6.4. Solenoid valve SDAJ213 (Coil Operated) Reset valve ....................................... 13

6.5. Solenoid valve DSA210(3/2 PILOT OPERATED) ................................................ 14

6.6. Pressure switch .................................................................................................... 14

6.7. Anti Pinch Sensor (PDV) ...................................................................................... 15

7. Trouble shooting ................................................................................................... 16

7.1 Additional Information ........................................................................................... 17

8. Packaging & store ................................................................................................ 18

9. Assistance ............................................................................................................ 18



1. Introduction

Thank you for choosing ROTEX product. Each product is fully inspected after the

production to offer you the highest quality. In order to fully utilize the product, we

strongly recommend users to read this manual carefully and understood.

This manual provides information on installation; operation and maintenance

procedures and related instructions for the ROTEX make Bus door systems.

The aim of this literature is to support the use of products in correct manner,

and all the technical information provided in the catalogue.

The manual should be given to the end user.

The manual can be changed or revised without any prior notice. Any changes

in product's specification, structure, and/or any components may not result

immediate revised version of the manual.

The manual should not be duplicated or reproduced for any purpose without

any consent of Rotex Manufacturers & Engineers Private Limited, INDIA.

Manufacturer Warranty

For the safety, it is vital to follow instructions in the manual. It is not ROTEX’s

liability for any damages which caused by users' negligence.

It is not ROTEX's liability for any damages or accidents which resulted by any

alteration or modification of the product and parts. If alteration or modification

is necessary, please contact the ROTEX directly.

ROTEX warrants the product from the date of original retail purchase of the

product for one (1) year, except as otherwise stated.

ROTEX warranty will not cover the products that the product have been

subjected to abuse, accident, alteration, modification, tampering, negligence,

misuse, faulty installation, lack of reasonable care, repair or service in any

way that is not contemplated in the documentation for the product, or if the

model or serial number has been altered, tampered with, defaced or

removed; damages that occurs in shipment, failure due to power surge, and

cosmetic damage. Improper or incorrectly performed maintenance or report

voids this Limited Warranty.

For detailed warranty information, please contact:

ROTEX MANUFACTERURS & ENGINEERS PRIVATE LIMITED, Manapada

road, Dombivli (e), Maharastra, India, Pin – 421204.



1.1. Definitions

WARNING:

If not observed, user incurs a high risk of severe damage to product and/or fatal injury to personnel.

CAUTION:

If not observed, user may incur damage to product and/or injury to personnel.

NOTE:

Advisory and information comments provided to assist

maintenance personnel to carry out maintenance procedures.

2. Operation principal It is improved driving mechanism for opening/closing the door of the buses. It is

featured with compact structure, fine performance and long life service. It uses

electrical as well as pneumatic systems for opening/closing of the door.

Pneumatic control systems can be designed in the form of pneumatic circuits. A

pneumatic circuit is formed by various pneumatic components, such as

cylinders, directional control valves, flow control valves, etc. Pneumatic circuits

have the following functions:

1. To control the injection and release of compressed air in the cylinders.

2. To use one valve to control another valve.

Similarly, Electric control systems can be designed in the form of electric

circuits. An electric circuit is formed by various electric components, such as

micro processor, switches, control box etc. Electric circuits have the following

functions:

1. To control the controller operation.

2. To trigger the solenoid valve.



3. Identification

4. Installation procedure

The equipment must be installed in the accordance with the laws, guide

lines and rules applicable within the country.

CAUTION:

Do not dismantle the cylinder while operation is in line.

Do not allow dirty air or fluids to get into the cylinder.

NOTE:

Ensure the installation meets the legal and regulatory

requirements of the country and state of use.

The door assembly should be left in the original packing until it is

required for the use.

Operating pressure range 4-10 bar.

Operating temperature range -20°C to +80°C

Check the components as per packing list before installation.

Make sure that sealing gasket and glass have been installed on

the door panels.



Drawings





1. First install top mounting plate assembly by mounting the screw through

plate into the bus frame at its position as per drawing.

2. Install the sealing gasket on bus frame. Fix it using stiffener plate with self

tapping screw.



3. Mount the bracketed support shaft perfectly vertical by pushing shaft head

into bearing of the mounting plate and tight the bracket at the bottom.

4. Mount the brackets and handle on the door panel as per the drawing. And

then install the door panel on the bus frame one by one by mounting door

panel into arm brackets of door shaft.



5. Install the guide rollers properly, to align door with structure to avoid gap

adjust eccentric roller shaft.

6. At last install the brush.

7. Manually close and open the door to check its smooth movements.

8. Connect the pneumatic tube and electrical wire as per drawings.

9. Open and close the door automatically to check whether the door moves

smoothly. If needed, adjust the speed and cushioning.

Initial adjustment

When door closes, disconnect its connection

with cylinder. Pull the cylinder rod outside 5

mm approx and again join the disconnected

connection. Now close the door. This will

ensure tight closing of the door.

Locking position

After initial adjustment, mark the locking position at closed door position.



Electro-Pneumatic circuit diagram



5. Maintenance

NOTE:

ROTEX recommends “ROTEX V09” grease for greasing. Apply the

grease with soft brush or similar.

In case of any difficulty consult ROTEX distributor.

1. Install, operate and maintain as per the instructions and recommendations of this manual.

2. Observe grease layer on moving parts weekly. 3. While observing apply grease on the moving parts if necessary.

6. Characteristics parts

6.1. Cylinder Ø63/100

Function: Drive the door to open and close Specification:

Working Medium Filtered compressed air (Min 50µ)

Pressure range 1 – 10 bar

Front fixing Ball & Socket joint

Rear fixing MP4

Ambient temp. -20 °C to +70 °C

Cushioning adjustment Both ends

6.2. Solenoid valve SVAJ214 (Coil Operated)

Function: Drive the cylinder to open and close Specification:


Position 5/2

Pressure range 1 – 10 bar


Response time - @5bar

On time 20 msec., off time 22 msec.

Orifice 6.0mm

Mounting Through holes in housing, also suitable for mounting on manifold

Flow rate 290 l /min

Connection 1/4” BSP inlet/outlet 1/8” BSP exhaust



6.3. Pneumatic emergency valve

Function: Used for exhaust the system pressure to open the door manually. There are two type of cover proved in which the emergency valve fitted. The round cover installed near the doors at outer side of bus and the square ones inside.

6.4. Solenoid valve SDAJ213 (Coil Operated) Reset

valve

Function: Used to reset the system after emergency

Specification:

Working Medium

Filtered compressed air (Min 50µ)

Position 3/2

Pressure range

2.5 – 10 bar

Ambient temp.

-10 °C to +70 °C

Response time -@5bar

On time 20msec., off time 22msec.

Orifice 3.0mm



Connection 1/4” BSP INLET/OUTLET



6.5. Solenoid valve DSA210(3/2 PILOT OPERATED)

Function: Used to maintain air flow in the system Specification:

6.6. Pressure switch

Function: To give feedback the system after obtaining requires pressure in the system for operation.

Specification


Range / Set point 0 -10 bar / 1 bar


Mounting On the bracket

Connection 1/8” BSP (F) x 8/6 PU tube Conn.


Pressure range 2.5 – 10 bar


Response time -@5bar

On time 20msec., off time 22msec.

Orifice 3.0mm



Connection 1/4” BSP INLET/OUTLET

Pilot Pressure



6.7. Anti Pinch Sensor (PDV)

Function: Whenever there is any obstruction at

the door, due to the difference of air pressure in

the cylinders, the mechanical switch operates

and that signal is sensed by the controller thus

making the door retract automatically.

6.8. Beeper With Indicator

Function: During the door closing, the buzzer beeps to warn the driver. And also in case of emergency the beeping frequency changes to warn the driver.



7. Trouble shooting

No. Trouble Cause Solution

1. Door not working.

Leakage in cylinder Tight the fittings.

Solenoid valve failure. Check as per manual/replace.

Controller wiring harness is damaged.

Correct the harness connection.

Check the on/off switch on the dash board for proper functioning.

Check the connections and wiring/Check on/off switch contacts/ replace the switch.

Low pressure at the main cut off valve

Start the engine to build pressure or else check for bending in pipe line.

2. Emergency Switch

Continues air exhaust but not achieved emergency condition.

Check button (Manual condition) of SDAJ213 (Reset valve) whether it is in pressed condition. It should be in unpressed condition only.

3. System Reset problem

Pressures switch connection loose.

Check the connection of pressure switch.

4. Ant pinch function not working

PDV sensor connection loose Correct the connection of PDV sensor on cylinder.

5.

Door open/close either too fast/slow.

Flow control not adjusted. Rotate the knob of the flow control to adjust the air flow.

Cushioning screw adjustment. Adjust the cushioning screw to avoid jerks during door close/open.



7.1 Additional Information

1. Reed switch position – Reed switch assembled as per above picture. It is

always on rear side of the cylinder in in-swing door.

2. 5/2 double solenoid valve- The open & close coil as per above picture

(View from inside of the bus). If it is not functioning properly please check

tubing routing of the system (Refer electro-pneumatic diagram).

3. Pressure difference valve (PDV) – PDV can be set by grub screw

adjustment

Clockwise rotation – Less sensitivity

Anti-clockwise rotation- High sensitivity



8. Packaging & store 1. When not in use, DOOR ASSEMBLY should be kept in a sealed plastic

bag in a cardboard box to prevent moisture or dust from contacting product.

2. DOOR ASSEMBLY should be stored in a dry place free from water and dust.

3. Store at temperature between 40°F and 120°F (4°C and 49°C). 4. Locate in an area to avoid damage by impact.

9. Assistance For technical questions or assistance, contact any authorized distributor of ROTEX Or ROTEX MANUFACTURERS AND ENGINEERS PRIVATE LIMITED Manpada Road, Dombivli (East)-421204 Maharastra, INDIA. Tel: +91 251 2871033/ 2871390/ 2871196/ 2871989 Fax: +91 251 2871191

[email protected]

Documents

BUS DOOR SYSTEM - Rotex | High Pressure Solenoid ...rotexautomation.com/downloads/IOMs/pneumatics/RTX-IOM-BDOS.pdf · ELECTRO-PNEUMATIC IN-SWING BUS DOOR CONTROL MECHANISM Installation