CAME UNITED KINGDOM LTD UNIT 3 ORCHARD PARK INDUSTRIAL ESTATE, TOWN STREET, SANDIACRE, NOTTINGHAM NG10 5BP

TEL: 0115 921 0430 FAX: 0115 921 0431 INTERNET - www.cameuk.com E-MAIL - enquiries@cameuk.com

TECHNICAL HELPLINE 0115 921 0430

0 0 0 6 G D R GA
ions t c u r t s n I n Installatio d barriers oa for swift r

THE GARD KIT CONSISTS OF:

BARRIER UNIT CONTROL PANEL ALUMINIUM BARRIER ARM RED PHOSPHORESCENT STICKERS SAFETY BEAM POST SAFETY BEAM

INTRODUCTION
THESE INSTRUCTIONS WILL SHOW YOU HOW TO INSTALL A GARD AUTOMATION SYSTEM FOR SWIFT ROAD BARRIERS. PLEASE READ THESE INSTRUCTIONS AND DIAGRAMS CAREFULLY BEFORE STARTING ANY WORK.

UNDER NO CIRCUMSTANCES SHOULD THIS EQUIPMENT BE OPERATED UNLESS FITTED TO A GATE.

FAILURE TO COMPLY WILL INVALIDATE THE GUARANTEE.

GENERAL SPECIFICATION
DESCRIPTION:
This unit can be used to control entrances up to 6.5 metres wide (with accessories on the barrier up to 6metres). Designed and constructed by CAME in compliance with current safety standards (UNI 8612) and with an IP54 protecting rating. Guaranteed for 12 months unless tampered with by unauthorised personnel.

MODELS:
G6000. Barrier with non-reversible 24V DC gear motor, case in galvanised steel with enamel finish, control panel and internal drive system. OPTIONAL ACCESSORIES: G0601 Rectangular cross-section, 100x40x6850mm aluminium barrier with white enamel finish. G0602 Tubular cross-section, 100mm dia x 6850mm aluminium barrier with white enamel finish (recommended for areas subject to strong winds) G0603 Red anti-collision bumper strip with end caps, for G0601 barrier. G0460 Pack of 6, 24V DC signal lamps with brackets for fitting to G0401 barrier with flash control circuit board. G0461 Red phosphorescent stickers for barrier. G0462 Non-moving support for barrier. G0463 Moving support for barriers. G0465 White enamelled aluminium fencing for barriers. G0467 Joint for G0601 barrier. G0468 Support for attachment of safety beam to casings. G0469 Support for attachment of flashing light assembly. ATTENTION! For ease of installation and conformance to current safety norms, we recommend installation of CAME safety and control accessories.

TECHNICAL CHARACTERISTICS

TYPE

WEIGHT POWER KG SUPPLY 230V AC 24V DC

CURRENT DRAW 1.3A-230V 15A-24V

MOTOR POWER 300W

DUTY REDUCTION MAX TIME CYCLE RATIO TORQUE HEAVY DUTY

G6000 G6001

72

1/202

600Nm

4-8s

EXTERNAL DIMENSIONS

450 = = 295

1077

460

240

914

TECHNICAL DESCRIPTION
A Case constructed in 2.5mm galvanised stainless sheet with an enamel finish (G6000), or in 2mm stainless steel, with a satin finish (G6001), factory configured to accept all required accessories. The access door for inspection can be locked onto the case with a personal key. Mounting base in galvanised steel with anchor stays and bolts for anchoring the case to the baseplate. The flange is in galvanised steel. This holder allows the barrier to be quickly and securely locked. Manual release system. Motor: 24V DC reduction gear, non-reversible with die-cast aluminium housing and is permanently lubricated with liquid grease. A spring acts as counterbalance for precise uniform movement. An internal shock absorber/travel stop is provided. Limit switch assembly. Control panel (ZL37F)

C D E

F G H I

# H

$ G

Technic l description
4

INSTALLATION
Construct an adequate concrete base of the correct size for the installation of the unit. When pouring, sink the anchoring stays and the mounting base for the unit into the concrete. The concrete base must be perfectly level and clean from end to end. All screw threads must be completely accessible from the surface of the concrete base. The electrical cables from the unit must also protrude from the base. When the concrete is set place the unit on the base. It is good practice to have the inspection door on the inside of the property. Tighten the unit down and check for level. Fit the barrier arm and adjust the mechanical stops to stop the arm in the desired position.

B A

240

140

380 460

Mounting base for case

Cable exit

COMMISSIONING
1. Ensure that the barrier is securely fastened to the base plate with the bolts provided. It is good practice to install the barrier so that the access door is on the inside of the installation. 2. First determine the length of our barrier arm the insert the arm into the holder and secure with the four allen screws provided. Adjust the mechanical stops B and C to obtain the desired vertical and horizontal positions. (see figure 1)

B A

3. The G6000 Barrier is supply with both springs installed in position B. If the final configuration of you barrier requires a spring change follow the illustrations below.

Lm
Spring Positions

<4 1A

<5 1A

<6 1B 1B

<6.5 1A

Lm
Spring Position

<4 1A

<5 1B

<6 1A 1B

A
With skirts or Mobile support Spring attachment Points

Lm
Spring Position

<4 1B

<5 1A 1B

<6 2B

4. Unlock the gearmotor and change the position of the springs (do not throw away the spring if not used) 5. The barrier arm should be balanced at 45 for the barrier to work correctly. 1) Manually release the gear motor by using the manual release key. 2) Loosen locknuts B on the tension rods A. 3) Manually adjust the springs to increase/decrease their tension until the barrier arm is balanced at 45. 4) Now tighten the locknuts and re engage the gear motor by using the manual release key.

A
200 max

80 max

6) 7)

Connect mains power to terminals L1 and L2 and connect to a suitable earth. Set all dipswitches off accept 8 and 9 ON for commissioning and insert a wire link between terminals 2 and C1 8) Set potentiometer SENS to the halfway position for commissioning. 9) Set potentiometer TCA to minimum for commissioning 10) Set the Transformer as follows for commissioning: - SPEED to minimum and DECLERATION to minimum.

Deceleration

Speed

C O M

Max

Min

Min

Med

Max

To set the speed and deceleration, move the faston connectors A and B onto the indicated terminals

11) Ensure that the barrier arm is locked in the 45 position. 12) Momentarily pulse terminals 2 and 3 and the barrier should move to the open Position. Once the barrier is in the up position pulse terminals 2 and 7 to make the barrier come down. 13) Prove and adjust the open and closed limit stops to the desired position.

14) Check the sensitivity of the barrier by physically trying to stop the barrier when it is moving to the closed position, If the arm is easily stopped the power needs to increased by turning potentiometer SENS more to the minus position.

TRIMMER SENS

15) If automatic closing is required move dipswitch 1 to the on position and adjust potentiometer TCA until the desired time is achieved. 16) If safety beams or induction loops are used to prevent the barrier closing onto vehicles, remove the wire link between terminals 2 and C1. This will give you re-opening during closing. 17) If Emergency stop is required insert the safety device (normally closed) into terminals 1 and 2 and move dipswitch 9 to the OFF position. 18) If a closed only button is required move the jump strap that is positioned between the terminal blocks to the number 4 position. This will give you closed only on terminals 2 and 7. 19) If a full-length barrier arm is fitted with accessories it is advised to use the increased braking facility by moving dipswitch 10 to the OFF position.

10

TROUBLE SHOOTING
Fault Barrier goes up but will not go down Action If NO safety devices are fitted check that there is a link fitted between terminals 2 and C1. If safety devices are fitted check that they are giving a closed circuit when the are working normally. Check that the barrier is balanced at the 45when the barrier is manually released. Check that the barrier sensitivity is set correctly and adjust accordingly. (minimum sensitivity gives you maximum power) Check all of the above Check that the increased braking facility has not been used (dipswitch 10)

The barrier stalls when moving up or down

The barrier arm stalls when a short arm is fitted

TECHNICAL HELP LINE 0115 9210430

11

TECHNICAL DESCRIPTION OF ZL37F CONTROL PANEL

This control board is powered by 230V a.c. across terminals L1 and L2, and is protected by a 3.15A fuse on the main power line. Control systems are (24) powered by low voltage and protected with by a 2A fuse. The total power consumption of 24V accessories must not exceed 20 W.

SAFETY
Photocells can be connected to obtain: a) Re-opening during the closing cycle; b) Total stop: the movement of the bar is interrupted, and the automatic closure cycle is disactivated. Use the keyboard or the radio transmitter to resume movement of the bar; - Amperometric safety device: see NOTE; - Fixed operating time of 20 sec.

OTHER FUNCTIONS
- Automatic closing: The automatic closing timer is automatically activated at the end of the opening cycle. The preset, adjustable automatic closing time is automatically interrupted by the activation of any safety system, and is deactivated after a total stop command or in case of power failure; - Immediate closure (the bar is lowered automatically after the vehicle has passed the safety devices, on the terminals 2-C5 of the control panel; - "Operator present" function. Bar operates only when the pushbutton is held down (the radio remote control system is deactivated); - Obstacle detection: When the motor is stopped (bar is closed, open or half-open after an emergency stop command), the transmitter and the control pushbutton will be deactivated if an obstacle is detected by one of the safety devices (for example, the photocells); - Flashing light activated before opening and closing cycle begins; - Activation of a 24V output signal during the movement phases and in the closed position; - "Slave" operation when two motors are used in combination (see page 22); - Increases the braking action on the barrier; - Selection of command sequence: open-close, open only.

ACCESSORIES CONNECTED IN SERIES

- Flashing signal light (25W max.), when bar is in motion.

OPTIONAL ACCESSORIES
- Open barrier pilot lamp (3W max.). This is a light that indicates the barrier open position and turns off when the barrier activates the closing end-stop (terminals 10-5); - LB35 board, used to power the automation system using battery power in case of a power failure. When the power supply is restored, the batteries are recharged automatically (refer to instruction sheet);

ADJUSTMENTS
- Sensitivity of amperometric safety system: min./max. - Automatic closing time

12

ZL37F MOTHERBOARD
M
M ax. M i n. M i n.M ed. M ax.

" B"

" A"

L1T L2T

PT

3 4

5 6

8 9 10

QU ADRO CO M AND O

ZL 37

MAIN COMPONENTS
1 2 3 4 5 6 7 8 9 10 11 12 Terminal block for external connections 3.15A line fuse 2A accessories fuse "Function selection" dip-switch Radiofrequency board socket (see table) TCA trimmer: automatic closing time adjustment SENS trimmer: amperometric sensitivity adjustment Button for memorizing code numbers Radio code / automatic closing signal LED Connectors for power supply motor Connectors for connection to battery charger (LB35) Jumper for selection of type of control for button in 2-7

13

DIPSWITCH SELECTION OF FUNCTIONS

L1 L2 L1T L2T PT

Vel .

Rall .

2 3 4

5 6

8 9 10

QU ADRO CO M AND O

ZL 37

ON OFF

ON 1

5 6

9 10

1 ON 2 ON

Automatic closure enabled; "Only open" radio control or pushbutton function enabled (with plug-in radiofrequency board);

2 OFF "Open-close-reverse" radio control or pushbutton function enabled (with plug-in radio frequency board); 3 ON 24V output voltage on 10-E terminals when the barrier is in motion and in the barrier's closed position, enabled;

3 OFF 24V output voltage on 10-E terminals when the barrier is in motion, enabled; 4 ON 5 ON 6 ON 7 ON "Operator present" function enabled; Pre-flashing (aperture and closure) enabled; Obstacle detection device (motor of limit position) enabled; "Slave" operation (motor is controlled externally) enabled;

8 OFF Immediate closure function enabled; activate safety device (2-C5); 9 OFF "Stop" button enabled; activate safety device (1-2); 10 ON Function that increases the braking action on the barrier enabled;
14

PROGRAMMING THE REMOTE CONTROLS

T432S (MINI-PINK) Remotes Remove the battery cover off of the remote and change the Factory set code to a unique code for the installation via the 10 dipswitches. Insert the frequency card into the control panel (item 5 on motherboard). Identify the little yellow button on the motherboard and press and hold the little yellow button in and an LED will flash. Then press the button on the remote control you wish to operate the equipment with and then let go of both buttons. Make sure any additional remotes are the same code. You do not have to program these into the board - they should work.
actionning LED
"AF" BOARD

ON
1st key fixed on channel 1

OFF
NS. -

- T.C.A. -

MOTHERBOARD

Code selection dipswitch: set the same code programmed on receiver

ON 1

5 6

9 10

Channels Scheme

1
Channels selection jumpers 4 pins strip 2nd key preset on channel 2; put the jumpers as shown in figures to change

Channel 1

Channel 2

3
Channel 3
15

Channel 4

PROGRAMMING THE REMOTE CONTROLS

Use on existing system
(with TOP at 433.92 MHz) 1. Press the key to encode until, after 7 seconds of flashing, the red signalling LED remians on. (fig A) Within 10 seconds, bring the existing transmitter closer from the rear part and press the pushbutton you want to copy for a few seconds. (fig B) Once it has been saved, the LED will flash 3 times and the transmitter will be ready for use.

A
2.

Repeat 1 and 2 for the other pushbuttons. (NB: the code of another system can be saved).

Use on new system

Consult the documentation of the electric board to save the first transmitter, then follow the procedure described above to duplicate it in the quantity desired.

Red signalling LED

To open battery compartment, press and slide.

16

ZL37F ELECTRICAL CONNECTIONS

E+ 10-11 1 2 3 5 7 C1C5 INTERBLOCCO FA FC F PT M N

L1 L2

230V (a.c.) power supply

M N

24V (d.c.) motor

10 E

Uscita 24V in movimento (es.lampeggiatore - dip 3 OFF) DIP 3 24V output in motion (e.g. flashing light - Pos. B Jumper) during movement (e.g. flashing light) OFF Sortie 24V en mouvement (ex. branchement clignotant - Jumper Pos. B) Ausgang 24V in Bewegung (z.B. Blinker-Anschlu - Jumper Pos. B) 24V output Salida de 24V en movimento (ej. l mpara intermitente - Jumper Pos. B)

during movement and in the closed position

DIP 3 ON

10 5

24V -3W max. "bar-opened" signal lamp

10 11

Power supply accessories (max. 40W): 24V (a.c.) with power supply at 230V (a.c.) 24V (d.c.) with power supply at 24V (d.c.)

N.B. When connecting the photocells (TX and RX), observe the correct polarities.

TX

RX

NO C NC

1 2

10 11

Pushbutton stop (N.C.)

17

ZL37F ELECTRICAL CONNECTIONS

2 3
Open pushbutton (N.O.)

JUMPER
Collegamento radio e/o pulsante (N.O.) per tipo comando, vedi dip-switch 2 Connector (N.O.) radio and/or pushbutton. See DIP 2 for command type Connector (N.O.) radio and/or pushbutton see dip-switch 2 for command type Connection radio et/ou bouton-poussoir (N.O.) pour commande voir dip-switch 2 Anschlu Funkkontakt und/oder Taste (N.O.) Steuerart siehe dip-switch 2 Button operation: closure only Conexin radio y/o pulsador (N.O.) para mando mirar dip-switch 2

2 7

JUMPER

2-C1 2 C1
Contact (N.C.) for re-aperture during closure if not used
E 1 0 1 1 1 2 3 5 7 C1 C5

dip 8 ON 2 C5
Contact (N.C.) of immediate closure if not used

F FA

Connection microswitch deceleration opens

F FC

Connection microswitch deceleration closes

Antenna connection

18

ZL37 BARRIER SPEED ADJUSTMENT

C O M

DECEL SPEED

ARM SPEED

Max Min Min Med Max

To set the barrier speed and deceleration, move the faston connectors A+B onto the indicated terminals

19

CONNECTION FOR TWO COMBINED MOTORS CONTROLLED TOGETHER

SX DX

CA ME

1) On one of the two control panels, set Dip 7 to ON in order to select the motor controlled externally (slave).

1)

Slave motor 2control panel

Dc e e l a r o n i t a l R e n a m t e n o t a n R e t l s s i me e n t Gs c e h w . b A a n m h e De c l r c e a n i
C O M

S p e e V o c l i t d i t V s s e e Gs c e h w . e l V c a o d d i

Mx a . Mi n .M i n . Me d . Mx a .

B " "

A " "

V e . l R a l .

n e f i l u e s mo t r f o u s e a c s e s o r i s e f u s e

Z L 3 7

Dc e l r a e o n i t a n R e t l s s i me e n t De c l r a e n i c p e d S i t V s s e e e c V o a l d d i

B " "

A " "

V e . l R a l .

2) Wire the electrical connections only on the terminal board for the pilot motor in the normal.

2)
C O M
Decelera ti on Rallent amento Ralent iss emen t Geschw. Ab nahme Decelera ci n Speed Ve locit Vi tes se Geschw. Velocid ad

M ax. M in. M in. M ed. M ax.

"B"

"A"

(pilot) motor 1terminal block

L1 L2 L1T L2T PT

Ve l.

Ra ll. line f use m o to r fu se a cce sso rie s f use

1 C O N TR O LP ANE L

10

ZL 3 7

E+ 1 0-11 1 2

3 5 7 C1C5

INTERBLOCCO

FA FC F PT

M N

Decelerati on Ralent iss emen t

Speed Vi tes se Velocidad

Deceleraci n

3) Connect the two control panels using the interlock terminals as shown in the figure.

3)
L1
Decelera ti on Ral lent amento Ral ent iss emen t Geschw. Ab nahme Decelera ci n Spee eed Ve locit Vi tes se Geschw. Vel ocid ad

"B"

"A"

L2

L1T

L2T

PT

Ve l.
Decelera ti on Ral lent amento Ral ent iss emen t Geschw. Ab nahme Decelera ci n Spee eed Ve locit Vi tes se Geschw. Vel ocid ad

Ra ll.
C O M

C O M Max. Min. Min. Med. Max.

Max. Min. Min. Med. Max.

"B"

"A"

"B"

"A"

2
L1 L2

3 5 7 C1C5
ee

INTERBLOCCO

FA FC F PT

M N
L1 L2

E+ 1 0-11 1 2
ee

3 5 7 C1C5

INTERBLOCCO

L1T

L2T

PT

Ve l. Ra ll.

L1T

ad

L2T

PT

Ve l. Ra ll.

ad

line f use motor fuse accessories f u se

line f use motor fuse accessories f use

1 CO N T R O LP ANE L

10 CO N T R O LP ANE L

1 2

10

ZL 37

ZL 37

(pilot) motor 1terminal block

ee ad

Slave motor 2terminal block

ee ad

20

HANDING THE G6000 BARRIER

OUTSIDE

SX

DX

INSIDE

SX = With the barrier arm on the outside and the cabinet facing the inside of the property. This unit is usually positioned on the left. DX = With barrier arm on the outside and the cabinet facing the inside of the property. This unit is usually positioned on the right.

IF THERE ARE ANY PROBLEMS PLEASE CONTACT THE CAME TECHNICAL HELPLINE:

0115 921 0430

21

NOTES

22

CONTACT INFORMATION

CAME UNITED KINGDOM LTD UNIT 3 ORCHARD PARK INDUSTRIAL ESTATE TOWN STREET, SANDIACRE, NOTTINGHAM NG10 5BP TEL: 0115 921 0430 FAX: 0115 921 0431 INTERNET : www.cameuk.com E-MAIL: enquiries@cameuk.com THIS INSTALLATION WAS COMPLETED BY: ......................................................................... NAME.............................................................. ADDRESS........................................................ ......................................................................... ......................................................................... ......................................................................... TEL........................ MOBILE............................ DATE OF INSTALLATION................................