Industrial Roller Doors Motors

Types of Electric Motor Systems for Electric Roller Shutter Doors 

Any electric roller shutter door is usually driven by one of 3 types of electric motor systems.

Each has their limits and advantages in terms of operational speed, power requirements, number of operations per day ratings and other factors, such as motor size and positioning to enable installation with any site restrictions.

Controls for electric roller doors include the basic ‘hold to run’ push button system, which is what most electric doors use in non domestic installations simply because it is the cheapest, most reliable and easiest to set up system. One step further up is an ‘impulse’ control which enables the user to walk away once a button is pressed simply because the door has safety devices incorporated to detect the door hitting anything in its path when moving. When you upgrade to remote control or radar/loop detection controls the roller shutter safety is even more robust to detect even potential objects nearby in doors near public spaces.

The controls for any electric door all depend on the users and building requirements along with security and convenience, including perhaps operation out of hours for certain operatives.

So many variable controls are available these days, along with robust monitoring from within the motor and controls to log the activities of the door over time for simpler diagnosis and maintenance.

Here are the 3 main types of roller shutter electric motor drive systems:

Single phase power, just like the tube motor, has more limited weight handling and therefore limited size ranges for the doors.

Single phase power however is usually easier to manage and also to add on additional controls.

Obviously the size of the motor is determined by the power and torque output required and output torque can vary from around 60Nm to around 5000Nm on the largest motor drives.

Anti-fall back devices can be integrated into the motor as an overall package to comply with regulations where required, otherwise it is an external and separate device.

Understanding Motor Duty Cycles and Usage Ratings

When selecting a motor for an industrial roller shutter, understanding the 'duty cycle' is crucial to prevent premature motor failure. The duty cycle refers to the percentage of time a motor can safely operate within a given timeframe without overheating.

• Low Usage (Tube Motors): Suitable for shops or small commercial units operating 2 to 4 cycles per day. These motors have built-in thermal cut outs that stop operation if they overheat.
• Medium Usage (Single Phase Chain/Direct Drive): Ideal for agricultural buildings or light industrial units, capable of handling 15 to 20 operations per day.
• High Usage / Continuous (Three Phase Direct Drive): Required for busy distribution centres, car parks, or automated factories. These motors often have a 60% to 100% duty cycle, meaning they can operate almost continuously without overheating.

Single Phase (240V) vs. Three Phase (400V) Power

Your site's power supply will often dictate your motor options:

Single Phase (240V): The standard power supply found in domestic and light commercial properties. It is sufficient for tube motors and smaller chain driven doors. However, single phase motors draw higher current upon start up, generating more heat, which limits their suitability for high-speed or constant-use applications.

Three Phase (400V): The standard for industrial environments. Three phase power provides a smoother, more consistent flow of electricity. Motors running on three phase power generate less heat, run more efficiently, and are essential for large, heavy roller doors or doors that need to open and close constantly throughout the day.

Safety Features and Compliance

All automated industrial roller doors in the UK must comply with strict safety regulations, most notably BS EN 12453 (Safety in use of power operated doors). When specifying a motor, it must work in tandem with the correct safety devices:

• Anti-Fallback Devices (Safety Brakes): A legal requirement for any door that is not counter balanced. This device prevents the heavy door curtain from unrolling and plummeting in the event of a motor or gearbox failure. Many modern direct-drive motors feature built in, patented safety brakes.
• Safety Edges: An optical or resistive sensor housed in the bottom rubber seal of the door. If it detects an obstruction while closing, it instantly stops and reverses the motor. This is essential for doors using 'impulse' (one-touch) controls.
• Photocells and Light Curtains: Infrared beams placed across the door opening. If the beam is broken by a person, vehicle, or forklift, the motor will not operate.

Emergency Manual Overrides

Power cuts happen, but your business still needs to operate. It is vital to ensure your electric roller door motor features an emergency manual override. For tube motors, this is usually a simple winding crank. For larger chain drive and direct drive industrial motors, a low-level hand chain operation is standard, allowing staff to safely open or close the heavy door by hand until power is restored.

Choosing Trusted Motor Brands

At Samson Doors, we believe the motor is the heart of the door. We specify high quality drive systems from industry leading manufacturers to ensure longevity and reliability. For our commercial tube motors, we rely on established brands like Somfy. For our heavy duty industrial ranges, including the SeceuroDoor series, we specify GfA Elektromaten motors as standard. GfA drives are globally recognised for their precision gearboxes, built-in safety features, and digital limit setting capabilities.