Centsys D5-Evo, Installation Manual

Page 1: ...D5 Evo installation manual TM LIGHT INDUSTRIAL SLIDING GATE OPERATOR ...

Page 2: ...t connections 17 Earthing for effective lightning protection 18 Commissioning the system Setting the gate limits 19 How to set up additional features on the D5 Evo controller 20 Menu navigation map 21 Controller features 22 Factory defaults schedule 23 Description of terminal functions 24 Diagnostics Diagnostic LEDs Gate status LED LCD display Buzzer feedback 25 Fault finders guide 26 Manual opera...

Page 3: ...9 Add oil to gearbox page 15 Mount gearbox page 20 Mount rack page 21 Mount origin marker page 25 Apply warning decals page 27 These abbreviated instructions are for the experienced installer who needs a checklist to get a standard installation up and running in the minimum of time Detailed installation features and functions are referred to later in this manual page 1 ...

Page 4: ...Electrical setup page 2 step 1 1 Set gate end of travel limits step 13 Carry out professional handover to client Commissioning and handover step 12 Set additional features via the menus if required page 35 page 36 page 64 page 28 ...

Page 5: ...or fumes is a serious danger to safety Before attempting any work on the system cut electrical power to the operator and disconnect the batteries The mains power supply of the automated system must be fitted with an all pole switch with contact opening distance of 3mm or greater Use of a 5A thermal breaker with all pole circuit break is recommended Make sure that an earth leakage circuit breaker w...

Page 6: ...and be sure that they understand the hazards associated with automated gates Do not leave packing materials plastic polystyrene etc within reach of children as such materials are potential sources of danger Dispose of all waste products like packaging materials worn out batteries etc according to local regulations Always check the obstruction detection system and safety devices for correct operati...

Page 7: ... CLASS B Radiated emissions 150KHz TO 6GHz CISPR 22 CLASS B Conducted emissions 150KHz TO 6GHz Immunity IEC 61000 4 2 Electrostatic discharge IEC 61000 4 3 Radiated immunity 80MHz TO 1000MHz IEC 61000 4 4 Electrical fast transients burst IEC 61000 4 5 Surges IEC 61000 4 6 Conducted immunity 150KHz TO 80MHz Standard to which conformity is declared IEC 60335 1 2006 Safety IEC 61000 6 3 2006 Emission...

Page 8: ...tial opening Positive close mode Independent safety inputs for opening and closing beams Automatic beam test for both open and closing beams Advanced beam alarm functions Advanced lightning surge protection Timed courtesy light output Multiple pre flashing modes Independently adjustable motor speed in both opening and closing directions Onboard CENTSYS code hopping radio receiver with full channel...

Page 9: ...harging voltage 13 76V 170mA 10A 25 5kgf 17kgf 500kg 100m 18 22 m min Lockable door with key release 150 Input voltage Motor voltage Motor power supply Battery charger Current consumption mains Current consumption motor at rated load Operator push force starting Operator push force rated Gate mass maximum Gate length maximum Gate speed varies with load Manual override Maximum numbers of operations...

Page 10: ...f critical aspects that MUST be adhered to in order to prevent injury This icon denotes variations and other aspects that should be considered during installation Duty cycle mains present Operations in standby with 7Ah battery half day full day Operations in standby with 35Ah battery half day full day Collision sensing Operating temperature range Onboard receiver type Receiver code storage capacit...

Page 11: ...1 2 1 0 3 4 5 8 6 7 9 1 D5 Evo controller 2 Courtesy light fuse 3A F B 3 1 x 12V 7 2Ah battery 4 Gate mounted origin marker 5 Origin marker bracket 6 Origin sensor 7 Side covers 8 Foundation plate 9 Motor fuse 30A ATO 10 SM2A charger 11 Manual release access door 11 ...

Page 12: ...ation plate into concrete Pick Spade If bolting foundation plate onto existing plinth Drilling equipment Masonry bits to suit rawlbolts being used If welding foundation plate and or rack to gate Welding equipment G Clamp 6 inch x 2 If left hand side of gearbox is mounted close to a post Socket wrench Extension piece 17mm socket If fastening rack to gate Drilling equipment TEK screw socket page 10 ...

Page 13: ... the public There is sufficient clearance to a roadway and or public thoroughfares The installation will meet all municipal and or local authority requirements once completed The gate mass length and application is within the operator specifications The gate is in good working order meaning That it moves freely Does not move on its own if left in any position It can be installed to have sufficient...

Page 14: ...s fit anti lift brackets as shown The gap between the anti lift bracket and the gate must be less than 5mm Guide rollers Additional support post Ensure that the gate cannot be lifted off the motor pinion with the anti lift bracket fitted GAP 5mm GAP 5mm GAP 5mm GAP 5mm WARNING Endstops are mandatory and must be fitted to prevent death or accidental injury should the gate overrun its limits page 12...

Page 15: ...inuing to pull on the scale with just sufficient force to keep it running and read off the maximum value in kgf shown on the scale Where possible determine the gate mass The Centurion Systems Pty Ltd warranty will be void if the pull force and or gate mass exceed the operator specification as below Starting force 30kgf Running rated force 20kgf Maximum gate mass 500kg FIGURE 5 STARTING AND RUNNING...

Page 16: ...tional ground loop for free exit 1core 0 5mm multi stranded silicone coated n1 number of cores required by intercom n2 number of cores required by intercom Possibly increase cable thickness if pillar lights are installed Type of cable must adhere to municipal bylaws but typically SWA steel wire armoured cable is recommended The armouring provides excellent screening which gives better protection a...

Page 17: ...anges However in the event of the unit losing oil due to stripping down or mechanical damage the correct replacement oil is Castrol SAF X0 75W 90 synthetic final drive lubricant If the gearbox is bolted down in the horizontal position during filling the correct level is reached when the oil level is in the flat section of the dipstick Emptying the 80ml bottle of oil provided will give sufficient o...

Page 18: ...ure that the weight and pull force of the gate do not exceed the strength limit of the rack 10 Operator installation Locate operator position To ensure operator does not protrude into driveway install base plate at least flush with the driveway entrance Determine a suitable position and vertical height for the operator by considering Figures 8 9 and 10 It is typical to mount the rack above the pin...

Page 19: ...ustment Recommended to allow for adjustment 82 163 Foundation plate Foundation plate Flat bar welded to foundation plate and rail Raised foundation RAZ rack Nylon angle rack page 17 FIGURE 9A RAZrack above pinion FIGURE 10A Nylon angle rack above pinion FIGURE 9B RAZ rack below pinion FIGURE 10B Nylon angle rack below pinion Includes 3mm clearance required between rack and pinion Includes 3mm clea...

Page 20: ...ncrete plinth as in Figure 13 When using a concrete foundation it is recommended that the foundation plate is welded to the rail track of the gate using short length of flat bar as in Figure 12 This makes it possible to complete the whole mechanical and electrical installation without having to wait for the concrete to set After completing the installation the concrete can be poured and the operat...

Page 21: ... Existing concrete plinth Route cables and secure foundation plate 1 Route cables as determined in Section 8 Cabling requirements FIGURE 14 370mm 30mm M10 mounting bolts 2 Make sure that all cables and conduits protrude at least 400mm above the baseplate once installed as shown in Figure 14 Make sure that the M10 bolts which secure the gearbox are in place 3 Securely concrete or bolt the foundatio...

Page 22: ...e cables through these holes while fitting the gearbox to the baseplate 5 Note how the cables route up onto the control card 6 Check that the operator is level 7 Secure the gearbox in place fitting a washer spring washer and nut onto each gearbox mounting 8 Seal the conduit and knock out holes in the operator with silicone sealer to prevent ants from entering the operator through these cable entry...

Page 23: ...ely mounted to the side of the gate It must be parallel with the gate rail and there must be a 2 3mm gap between the teeth of the pinion 1 Before mounting the rack raise the operator an additional 3mm FIGURE 19 3mm RAISE FIGURE 18 Gate rail 3mm tooth gap Rack parallel to rail FIGURE 20 Mount the rack 2 Put gearbox into manual mode Refer to Section 26 for complete instructions Thumbwheel ...

Page 24: ...end ensuring that the rack is resting on the pinion not pressing down 8 Before fully fixing each section of rack slide gate backwards and forwards along the section checking that the rack is only resting on the pinion not pressing down 9 Continue this way to fix all sections FIGURE 22 Refer to the sections that follow for instructions on how to join the different types of rack FIGURE 23 3mm LOWER ...

Page 25: ...en joining different lengths of steel rack a simple way of ensuring correct pitch spacing is to clamp a small off cut between the two pieces RAZ rack 1 Fix the RAZ rack to the side of the gate using the TEK screws provided Use the vertical slots in order to allow adjustment 2 Use at least three TEK screws per half metre section of rack FIGURE 26 ...

Page 26: ...en D5 Fit additional fixing screw through the horizontal slots to secure the rack to the gate directly above the pinion when the gate is in the closed pedestrian and open positions FIGURE 27A FIGURE 27B Nylon angle rack 1 Fix rack to the side of the gate using the TEK screws 2 Ensure that all the mounting holes provided in the angle section are used FIGURE 28 Start on the right ...

Page 27: ...9 Butt firmly together Mount the origin marker 1 Close the gate completely FIGURE 30 2 Mount the origin marker to the rack a minimum of 500mm from the origin sensor Refer to Figure 31 isometric view A or plan view B It is possible to make the distance between the marker and the sensor much greater than 500mm However if using the pedestrian opening facility although the position of the marker will ...

Page 28: ...k the origin marker mounts directly on top of the rack without a bracket 7 Drill mounting holes directly into the rack and bolt into position 8 File away the front lip of the rack if you need to move the origin marker closer to the operator as the gate slides past FIGURE 33 RAZ rack 9 With nylon angle rack it is necessary to use the bracket provided 10 It is preferable to use self tapping fastener...

Page 29: ... face of marker and front face of sensor is between 13 and 20mm 16 Adjust distance by sliding the origin marker along the slotted mounting holes until the specified distance is achieved For best results keep gap between marker and sensor as small as possible Apply warning decal Apply the supplied warning decals to the gate as indicated on the reverse side of the decal ...

Page 30: ...y work 3 All electrical work must be carried out according to the requirements of all applicable local electrical codes It is recommended that a licensed electrical contractor perform such work 1 Connect all cables as required to the control card and battery charger according to the wiring diagrams as shown in Sections 12 to 16 that follow 2 Ensure that both the controller and the charger are effe...

Page 31: ...page 29 12 Wiring diagram for closing safety beam IRB Tx 12V 24V 12V 24V 12V 24V IRB Receiver COM 12V 24V NC NO Closing safety beam FIGURE 40 ...

Page 32: ...page 30 13 Wiring diagram for opening safety beam IRB Tx 12V 24V 12V 24V 12V 24V IRB Receiver COM 12V 24V NC NO Opening safety beam FIGURE 41 ...

Page 33: ...d and not the onboard receiver disable onboard receiver Menu 11 14 Wiring diagram for external radio receiver and loop detector Loop and loop detector 12V NEG COM NO NC Loop detector Loop 12V Remote control circuitry NEG COM NC NO External radio receiver FIGURE 42 ...

Page 34: ...diagram for other inputs Holiday lockout keyswitch keypad normally CLOSED Intercom pushbutton normally OPEN Pedestrian keyswitch keypad normally OPEN Pillar light pushbutton normally OPEN Status LED A U X A U X FIGURE 43 ...

Page 35: ...OF BATTERY CONNECTION FIGURE 46 SCHEMATIC OF LIGHT CONNECTION Battery 220 240V Mains in CP84 Charger Auxiliary connection on charger Earth to light casing FIGURE 44 Charger connection Battery leads Pillar light connection See Figure 46 below Red Black charger wires Charger 220 240V Mains in ...

Page 36: ... for effective lightning protection FIGURE 47 Earth spike 1m copper rod hammered into the ground Earth harness To CP84 220 240V Mains in to CP84 to CP84 to CP84 Spade connection Ring lug E N L Optional 40kA surge arrestor ...

Page 37: ...quest for the operating Profile operating standard to be set ZA Standard profile for South Africa CE Standard profile for the European Union UL325 Standard profile for the USA b Select the Profile that will suit the specific region from the list With this set the system will automatically proceed to the limit setup menu Follow the onscreen instructions to complete the setup procedure c If powering...

Page 38: ...ach step during the setup the function given to each button is provided on the display When not in setup mode i e normal mode the button is used as a test button for operating the system The triangular up or down buttons are used to scroll through the diagnostic screens For each feature a factory default setting has been programmed into the controller Referred to as an operating standard or profil...

Page 39: ... fully open 3 4 2 Autoclose partly open 3 4 3 Autoclose partly closed 4 Modes of operation 4 1 Operating mode 4 1 1 Standard mode 4 1 2 Condominium mode 4 1 3 Reversing mode 4 1 4 PLC 4 1 5 Deadman Control mode page 37 2 1 1 Opening collision force 2 1 2 Closing collision force 2 5 1 Indicator output 2 5 2 Closed indication 2 5 3 Part close indication 2 5 4 Closing indication 2 5 5 Part open indic...

Page 40: ...closing 6 4 IR beam alarms 6 1 1 PIRAC status 6 1 2 Stop on open 6 2 1 Status 6 2 2 Test beam 6 4 1 Ambush alarm 6 4 2 Break in alarm status 6 4 3 Alarm output 6 1 2 1 Stop on open status 6 1 2 2 Stopping distance 6 4 1 1 Ambush alarm status 6 4 1 2 Broken IRB time 5 Run profile 5 1 Positive close 5 2 Pre open delay 5 3 Pre close delay 5 4 Opening speed 5 5 Closing speed 5 6 Ramp up distance 5 7 R...

Page 41: ... 1 Delete remote by ID 11 2 2 Delete remote button 11 2 3 Delete remote by button 11 2 4 Delete not present 11 2 5 Delete all remotes 10 2 1 Factory defaults 10 2 2 Delete all remotes 10 2 3 Delete all time periods and exlusions 10 2 4 Reset all 9 ChronoGuard 9 1 Time and date 9 2 Time periods 9 3 Exclusions 9 4 Delete all Time periods and exclusions 9 2 1 Add Time period 9 2 2 Delete Time period ...

Page 42: ... independently per direction of travel Collision count A counter monitors the number of collisions that the gate experiences before it reaches the fully closed position If the value exceeds the value set in the multiple collision counter the controller shuts down until the next valid trigger is received As indication the status LED will flash four times every two seconds The multiple collision fau...

Page 43: ...e gate to open A trigger impulse on the Trg NO will cause the gate to close A trigger impulse on the Lck Stp NC will cause the gate to stop Autoclose override It is possible for the user to temporarily turn off Autoclose when the Mode of Operation is Standard or Reversing To activate Autoclose Override the Trg input must be activated and maintained for a period longer than the time set for the Aut...

Page 44: ...to 22 metres per minute Selecting maximum will move gate at maximum possible speed Closing speed Sets the maximum closing speed in metres per minute This can be set from 10 to 22 metres per minute Selecting maximum will move the gate at maximum possible speed Ramp up distance Sets the ramp up distance in centimetres of travel of the gate when starting This can be set from 10 centimetres to 10 metr...

Page 45: ...op on open function must be enabled The stopping distance setting then determines in centimetres how far the gate will run on after the beam has been broken The minimum setting is zero which will cause the gate to stop immediately after the closing beam has been broken The maximum setting is determined by the length of the gate PIRAC override The PIRAC feature can be temporarily disabled in the fo...

Page 46: ...hat TWO parallel closing beams are used to reduce the chance of false triggering Intruder breaks beam while loitering at gate Alarm Ambush alarm Activates an alarm if either the opening or closing beams have been continuously interrupted for a predefined time The alarm will remain activated while the beams are interrupted For example if a would be intruder covers the beams so that when the gate is...

Page 47: ...dependent on the pedestrian pre open delay and the time required for the gate to close from the pedestrian position is dependent on the pedestrian pre close delay Pedestrian open position Sets the maximum opening of the pedestrian gate in metres in one centimetre steps Pedestrian Autoclose time Sets the Autoclose time in seconds after a pedestrian opening This time can be set from zero seconds to ...

Page 48: ...re flash time before the pedestrian gate opens The courtesy light can also be controlled via the Auto activation function or the light time bar function as described in the ChronoGuard Time periods menu Menu 9 Courtesy light time The time that the courtesy light will remain activated can be set from four seconds to ten hours in one second increments Light profile The courtesy light can be selected...

Page 49: ...riod Free exit FRX Pedestrian opening Ped Holiday Lockout Lck Closing beam IRBC Courtesy light control Aux During the relevant time period the selected input will be activated Where appropriate the diagnostic LED of the relevant input will illuminate The following controller output can be set to activate automatically during a Time period Auxiliary output Aux IO Time barring Time barring of inputs...

Page 50: ...unction and time bar functions are deleted or removed Reset all Clears and defaults the system completely Unit will be reset to the factory default settings in addition to clearing all remotes and time periods Diagnostic screen Allows a diagnostic screen to be displayed This can be useful when troubleshooting but requires some technical knowledge Round test button Allows the round test button on t...

Page 51: ...ing sensitive functions such as Holiday Lockout on the controller Each transmitter learned into the system is assigned a unique transmitter ID Press valid button If the remote controls menu has been locked as discussed later only by pressing a button of a transmitter learned into the system can the remote controls menu be accessed Add remote Any button can be set to control the trigger pedestrian ...

Page 52: ... function of one button to perform another function For example button one s function is to open the gate completely To change this use the edit remote button select Ped and button one of the same remote will now only open the gate to pedestrian Autolearn Allows a selectable time period to be set during which any specific button when pressed will be learned to a specific function The function itse...

Page 53: ... 00m 00s 00m 00s 10m min 10m min 0 1m 0 1m 0 1m 0 1m 0 01m 4A 0m Parameter Description Menu 1 not applicable Menu 2 Opening collision force Closing collision force Collision count Alarm output LCK as ESTOP Menu 3 Autoclose status Autoclose timer Autoclose override time Autoclose from fully open Autoclose from partly open Autoclose from partly closed Menu 4 Modes of Operation Menu 5 PCM status PCM ...

Page 54: ... Break in alarm Alarm output Menu 7 PED opening PED Autoclose PED pre open delay PED pre close delay Menu 8 Light timer Light profile Menu 9 not applicable Menu 10 Diagnostic screen Round test button Menu 11 Delete Not Present Autolearn Tx Menu lock Onboard receiver Legend B Onboard buzzer C Condominium mode CL Courtesy light D Deadman Control Mode IRBC Closing safety beams IRBO Opening safety bea...

Page 55: ...te the gate status remotely If more than three LEDs are required it is necessary to fit the CP78 multi LED driver card For more details on the feedback about the status of the gate provided by the status LED refer to Section 24 Aux Activates the pillar light relay A normally open potential free input Momentarily connecting this input to Com will cause the light relay to energize for a period of ti...

Page 56: ...n Lck and Com refer to note on page 55 Safety Open Opening beam safety input A normally closed potential free input As long as a connection between this input and Common is maintained the controller will behave normally When this connection is broken it will prevent the gate from opening if it is stationary and will stop and close the gate if it is opening This input has no effect if the gate is c...

Page 57: ...ved the circuit which is affected must be replaced with a wire link to create the normally closed circuit Safe CommonUsed for switching the power supply to the safety beams If automatic beam testing is required the negative power supply connection of the beam transmitter only must be wired to this point In addition the beam test circuit must be switched on via Menu 6 See Section 21 Light light Pil...

Page 58: ... the opening beam is not activated Lck Stp green On when the Lck Stp input is not activated Trg red On when the trigger signal is present Ped red On when the pedestrian signal is present FRX red On when a free exit signal is present Aux red On when an auxiliary signal is present Status red This LED indicated the status of the gate as per the table below Off Gate is closed On Gate is partially or f...

Page 59: ... selected OVR if Autoclose is overridden and the remaining Autoclose time if Autoclose is active POVR indicates that the PIRAC option is overriden 4 Pillar light information Displays the remaining light time if courtesy light mode is selected Pre flashing mode is displayed if pre flash is selected LIT will be indicated if the pillar light has been turned on permanently 5 Onboard receiver informati...

Page 60: ... for 30 seconds 1 beep periodically for 30 seconds 5 beeps periodically for 30 seconds 5 beeps periodically for 30 seconds 5 beeps periodically for 30 seconds 5 beeps periodically for 30 seconds 5 beeps periodically for 30 seconds 4 beeps periodically for 10 seconds Periodic while gate runs 500 500ms Periodic until condition is cleared by user 500 500ms 3 beeps periodically for 30 seconds Priority...

Page 61: ...CD display then the operator is in Multiple Collision Mode If required check with procedure B False collision detection later in this section If the problem persists the main controller might be faulty Check the battery condition with procedure A Low battery voltage condition especially if the status light flashes three times or there is a Battery Low indication on the LCD display Check for false ...

Page 62: ...e magnetic origin switch is mechanically switching While in manual mode slide the gate backwards and forwards so that the magnet passes the switch each time Listen out for a distinctive click as the switch operates Also confirm the direction of the magnet using the relevant diagnostic screen e g magnet on the left or magnet on the right Check that the magnetic origin switch is securely clipped int...

Page 63: ...rectly to receiver If the battery voltage is less than 13 5V the motor would not operate at all For any other voltage the battery could still be the cause of the problem Is the battery being properly charged Check the mains present icon on the main diagnostic screen or switch to the battery charger diagnostic screen and check the charger voltage right hand value This should indicate xV Check that ...

Page 64: ... voltage on the battery leads It must be between 13 6V and 13 8V if not replace the charger Battery might be old and might have to be replaced If in doubt test as follows Check that the battery is charged by ensuring that the battery voltage is above 13 5V with the charger connected If the battery is in a good condition it would probably pass the test without being fully charged Disconnect the cha...

Page 65: ...s door is locked This secures the cover and prevents access to the inside of the unit which contains high voltages It also prevents theft of any components and provides full protection from the elements Do not remove the thumbwheel Removal of the thumbwheel may result in water entering the gearbox and the warrantee will be void Re engage gearbox drive 1 Rotate thumbwheel anti clockwise until thumb...

Page 66: ...ns NO ONE MAY CROSS THE PATH OF A MOVING GATE Always keep people and objects away from the gate and its area of travel NEVER LET CHILDREN OPERATE OR PLAY WITH THE GATE CONTROLS and do not allow children or pets near the gate area Be careful with moving parts and avoid close proximity to areas where fingers or hands could be pinched Secure all easily accessed gate operator controls in order to prev...

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