A10 Installation Manual
Company Profile Centurion Systems (Pty) Ltd, South Africa, has been manufacturing automatic gate systems since 1986, and is committed to providing reliable, cost-effective solutions in the field of gate and access automation. We offer a diverse range of products including gate motors, GSM-based products, garage door motors, remote controls, keypads, traffic barriers, proximity access control and intercom systems.
Important Safety Instructions ATTENTION To ensure the safety of people, it is important that you read all the following instructions. Incorrect installation or incorrect use of the product could cause serious harm to people. The installer, being either professional or DIY, is the last person on the site that can ensure that the operator is safely installed, and that the whole system can be operated safely. WARNINGS FOR THE INSTALLER 1.
Fast Track 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.
Fast Track Electrical Setup Action Step 1 Connect all wiring: Page 30 Step 2 Get into programming mode: Page 30 Fit the SET link. Briefly depress the reset button. Step 3 Set the gate limits: Page 30 Press and hold TEST, release after 1 flash of L1. Press and hold TEST, release after 1 or 2 flashes of STATUS. (1 flash = gate opens to the RIGHT. 2 flashes = gate opens to the LEFT). Step 4 Set additional features: (If required) Step 5 Exit programming mode: Page 32 Remove the SET link.
General Description The A10 is a heavy duty sliding gate operator designed to open and close sliding gates. In cases where chain, (as opposed to toothed rack) drive is required, an optional chain drive kit is available. The key to the A10's outstanding torque and duty cycle lies in the 3-phase induction motor and electronic inverter that form the heart of the system.
Theft Protection While care has been taken in the design of the A10 to prevent unauthorized removal (theft) of the unit, an optional steel theft resistant cage is also available for added peace of mind.
Specifications A10 BASIC SPECIFICATIONS Power Supply 220-240V +/- 10%, 50Hz - 1 Phase 6A Maximum Absorbed Current Motor Voltage 230V 3-Phase Output Pinion 20 Tooth Mod 4 Starting Thrust (Standard speed) 40kgF Rated Thrust (Standard speed) 30kgF Operating Speed @ Rated Thrust (Sprint speed) (Sprint speed) 30kgF 22.5kgF 1 16m/min Adj.
A10 ENDURANCE A10 HEAVY WEIGHT 220-240V +/- 10%, 50Hz - 1 Phase 220-240V +/- 10%, 50Hz - 1 Phase 6A 6A 230V 3-Phase 230V 3-Phase 20 Tooth Mod 4 17 Tooth Mod 4 (Standard speed) 40kgF (Standard speed) 30kgF 30kgF 47kgF 22.5kgF 35kgF (Sprint speed) (Sprint speed) 1 16m/min Adj. Up to 30m/min 13.
Duty Cycle Curves Calculating the duty cycle The duty cycle is the ratio of the actual operating time to the total time (opening plus closing plus pause times). The formula for calculating it is the following: To + Tc x 100 To + Tc + Tp + Ti opening time; closing time; pause time; interval between a complete cycle and the next Duty cycle % = where: To Tc Tp Ti = = = = A10 BASIC Duty Cycle Curves 4m 500kg gate @ 20kg pull force. Air temperature=25°C. Unit in full shade.
A10 ENDURANCE Duty Cycle Curve All speed combinations 4m 500kg gate @ 20kg pull force. Air temperature=25°C. Unit in full shade. Duty Cycle (%) 100 90 80 70 20 30 40 50 60 70 80 90 Time (Minutes) Figure 3 Duty Cycle Curves Examples of how to read the duty cycle curves: Referring to Figure 2, an A10 Basic, opening and closing at standard (STD) speed (n), can run at a duty cycle of 65% for 30 minutes, a duty cycle of 50% for 45 minutes, and a duty cycle of 45% for an unlimited time.
Product Identification The actual components supplied may vary depending on the model purchased. 1. 2. 3. 4. 5. 6. 7. 8. High Efficiency Fan* Inverter Module Inverter Fuse (F1 5A F/B) Logic Controller Fuse (F2 50mA S/B) Courtesy Light Fuse (F3 3A F/B) Manual Release Handle Lock Cover Logic Controller 9. 10. 11. 12. 13. 14. 15.
Required Tools & Equipment Electric Drilling Machine Spanners 17mm 13mm Screw Drivers: 3.
Site Considerations Install the gate operator only if: 1. It will not pose a hazard to the public. 2. There is sufficient clearance to a roadway and/or public thoroughfares. 3. The installation will meet all municipal and/or local authority requirements once completed. 4. The gate mass, length and application is within the operator specifications. 5. The gate is in good working order, meaning: That it moves freely. Does not move on its own if left in any position. 6.
End Stops FIT ENDSTOPS (1) CAPABLE OF STOPPING THE GATE MOVING AT RATED SPEED. MAKE HhTO ENSURE GATE WILL NOT JUMP OVER ENDSTOP. Figure 6 Gate End Stops WARNING Due to the high speed at which the A10 operator can move a gate, it is extremely important to install endstops capable of stopping the gate moving at the rated speed. Refer to Specifications as detailed on Page 8 for the operating speed.
Anti Lift Brackets Figure 7 Anti-Lift Brackets - Guide-rollers 2 must ensure that the gate is held vertically. - Fit suitable anti-lift brackets 5 . The gap 3 should be <5mm to ensure the gate cannot be lifted off the motor pinion. - For improved safety fit additional support post 4 to prevent gate from falling over if guide-rollers 2 fail.
Starting & Running Forces Figure 8 Starting and Running Forces 6 - The CENTURION warranty will be void if the pull force , and/or gate mass, exceeds the operator specification (see table below) Model Characteristic Starting Force Basic / Endurance 40kgF @ standard speed Heavy Weight 47kgF 30kgF @ sprint speed Running (rated) Force 30kgF @ standard speed 35kgF 22.
Cabling Requirements Mains isolator switch To dwelling LEGEND (3 core 0,5mm2 multistranded) 1. 220-240V AC mains cable via mains isolator switch (3 core LNE 1,5mm2)† 2. Intercom cable (n1 + 6 core) to house. 3. Radio receiver cable (3 core 0,5mm2 multistranded). 4. Pedestrian key switch (if required) (2 core 0,5mm2 multistranded). 5. Infrared beams or safety edge (if required) 6. Intercom cable (n2+2 core 0,5mm2 multistranded) to gate station. 7.
Operator Installation Foundation Plate Installation Rack/Axle Clearance Remember to insert mtg bolts, before fixing foundation plate. 28mm Minimum Foundation plate 43-48mm 16mm Dia round bar recommended Figure 10 Rack Axle Clearance Side Clearance Lower cover is approximately 5mm wider than chassis each side. Allow additional 20mm each side of lower cover if theft-resistant bracket is to be fitted.
Operator Installation Foundation Plate Installation - option 1 (Bolted down to existing concrete block) The LH concrete anchor 7 may need to be broken off in order to clear incoming conduits. Make sure the M10 bolts 8 which secure the gearbox are in place. Refer to the Fig. 10 to ensure correct positioning. Mark through the foundation plate holes to indicate where to drill holes for the M10 rawlbolts 9 . Use extra washers 10 as required to ensure the foundation plate is level.
Foundation Plate Installation - option 2 (Set in concrete) Figure 13 Foundation Plate Anchors The anchors 11 must first be bent down as shown in Figure 13. Use self locking or crimping pliers to bend the anchor tips 12 to the horizontal plane. Make sure the M10 bolts 13 which secure the gearbox are in place.
Important Information Lubrication The internal wormshaft/wormwheel gearset of the A10 is lubricated by means of an oil bath. ATTENTION In order to prevent possible leakage during shipping, the unit is shipped with no oil inside the gearbox. A bottle containing 80 ml of EP 80W90 oil is included with the product, and this MUST be introduced BEFORE operating the product. It is more convenient to insert the oil before bolting the unit down, as shown in Figure 15.
Operator Installation Gearbox Mounting Down Details Adjust jacking screws to give 4-6 mm chassis foundation plate clearance. (TIP: A 4mm allen key with a “Ball End” is handy). Check operator is level. Jacking Screw 4-6mm M10 Nut M10 Spring Washer 6mm Thick Load Spreader Assemble nut, spring washer, and load spreader as shown. Tighten nuts progressively i.e. left hand, then right hand, then left hand. Double check that jacking bolts are tight.
Joining/Mounting Rack - A simple way of ensuring correct pitch spacing when joining steel rack is to clamp a small off cut 14 between the two pieces. - Check that weld 15 does not foul with meshing surfaces. - Attach steel rack to gate using 25x25x5mm angle brackets 16 . - For best results support rack every 300mm. - Assuming the rail is level, the rack must also be mounted level with a 2 - 3mm clearance 17 . USEFUL TIP l l l l Raise gearbox by an additional 3mm.
Figure 18 Mounting Rack Page 25
Chain Drive Installation (Optional) Remove all four captive nuts from gearbox as shown.
Installing Chain Drive Systems 5 IDLER PULLEYS 4 >100mm 1 >100mm 2 3 Figure 20 Chain Drive Installation - Weld rear anchor plate onto gate such that centre line of tensioner pin is in line with top of the shaft on the idler pulley 4 . Allow at least 100mm between idler pulleys and anchor brackets. - Align fixed anchor bracket as for 1 . - Ensure chain direction over sprocket is as shown (see 5 ).
Origin Marker Mounting MOUNTING CONFIGURATION FOR STEEL RACK SECURE USING FASTENERS PROVIDED 18 WELD MOUNTING BRACKET PROVIDED TO STEEL RACK ORIGIN MARKER BRACKET 18 GREATER THAN 500mm 18 18 19 Figure 21 Origin Marker Mounting Page 28 m N 500m R THA TE GREA
- With the gate in the CLOSED position, mount the origin marker 18 a minimum of 500mm from the origin sensor 19 . (See Fig. 21 isometric view A or plan view B) - Manually slide gate OPEN until origin marker 18 is in line with the origin sensor 19 . Ensure distance between face of marker 18 and front face of sensor 19 is between 13 and 20mm. (See Fig. 21, view C) - Adjust distance by sliding the origin marker 18 along the slotted mounting holes until the specified distance is achieved.
Electrical Set-up WARNING 1. Always check that the circuit breaker in the electrical panel is in the OFF position, and that all high voltage circuits (more than 42.4V) are completely isolated from the mains supply before doing any work. 2. Ensure that all low voltage systems (Less than 42.4V) are suitably protected from damage, by disconnecting all sources of power such as chargers and batteries before doing any work. 3.
“Flip Out” Controller Mounting Controller enclosure vertical Controller enclosure raised Controller enclosure propped Figure 22 Controller Mounting Page 31
10. The gate will slowly open until it hits the open endstop, then slowly close until it hits the closed endstop. 11. The gate will then open at normal speed until the magnet passes the origin, and then slowly open until it hits the open endstop. L1 Indicator LED (See Fault Finder's Guide step 11) 12. The gate will then close at normal speed until the magnet passes the origin and then continue to close slowly until it hits the closed endstop. STATUS Indicator LED L2 Indicator LED TEST Pushbutton 13.
Get Into Programming Mode (Exactly the same as for limits setup) 18. Fit the SET link jumper to the SET pins as shown in Figure 23. 19. Press and release the RESET button. The STATUS light will flash five times. The SET and L2 lights will now be on. Your are now in programming mode. (See Fault Finder's Guide step 19) Selecting the Feature to Change (This is the first of two steps in setting a Feature. This only SELECTS the feature to change). 20.
Press and hold the TEST button while monitoring the STATUS light. The STATUS light will flash the same as for selecting a Feature. (See Step 21) Release the TEST button when the number of flashes is the same as the STATUS value required. Example 1 (continued): To set the MODE OF OPERATION to CONDOMINIUM: After selecting the Feature, again press and hold the TEST button while monitoring the STATUS light: The STATUS light will flash once and pause, then flash twice and pause…..
Example 2 (continued): At this moment release the TEST button to give a COUNT value of 10. This sets the autoclose timer to 10 seconds. L2 will come back on, indicating that the COUNT has been updated. Controller Features The terminology "FEATURE 2-2" refers to Feature number 2 with a status of 2. “FEATURE 3- COUNT” refers to Feature number 3, with a user specified COUNT value. Autoclose (FEATURE 2 - STATUS) This can be programmed ON (FEATURE 2-1) or OFF (FEATURE 2-2). The factory default is OFF.
CONDOMINIUM MODE (FEATURE 4-2) - Any trigger will cause a gate which is closed or closing to open or re-open. If not already active the Autoclose will automatically be turned on when Condominium Mode is selected. It is only the Autoclose signal, which can close a gate in Condominium Mode. If a trigger impulse is given while the gate is open the auto-close time is reset to its preset value.
the lights off. The gate will not trigger open when using the SET trigger. The fact that the pillar light is ON permanently is indicated by the STATUS LED flashing once every 2 seconds. When the PED input is triggered the Pillar Light flashes for an adjustable (1 to 255 seconds) pre-flash time (FEATURE 11-COUNT) before the pedestrian gate opens. (Default pre-flash time is 2 seconds). The contact can be used to operate a lamp, which will warn that the gate is about to open.
FEATURE13-2 Gate will open at standard speed + 30%. FEATURE13-3 Gate will open at standard speed + 60%. FEATURE13-4 Gate will open at standard speed + 90%. FEATURE14- 1 Gate will close at standard speed. FEATURE 14-2 Gate will close at standard speed + 30%. FEATURE 14-3 Gate will close at standard speed + 60%. FEATURE 14-4 Gate will close at standard speed + 90%. CUTOUT TIMER: (FEATURE 15-COUNT) The cutout timer will automatically shut off the motor after a predetermined time.
Procedure to Programme Controller Back to Factory Default Settings 1. Apply power. 2. Fit the "SET" link. 3. Connect "PED" and "FRX" to "COM". 4. Briefly depress the RESET button. STATUS light will flash five times, and then L1 and L2 will illuminate. 5. Remove the "SET" link and disconnect "PED" and "FRX" from "COM". 6. Briefly depress the RESET button. STATUS light will flash five times. 7.
Receiver Installation Figure 24 Receiver Installation NOTE: Although a space is provided for locating a radio receiver within the unit, best results will be achieved by mounting the receiver externally as high as possible.
Manual Release Operation A Manual release handle in closed position. Open lock cover and insert key. Turn key ¼ turn counter clockwise to unlock.
Manual Release Latching In the event of power failure, or product malfunction, it may be required to lock the cover in place whilst "latching" the manual release (i.e. manual release permanently enabled). This helps prevent theft of the unit, or its components, and provides full protection from the elements. Manual release latching is effected using a split pin as shown below. B A Split pin shown positioned.
CP201 Trigger Connections (LED’s) 12V COM TRG IRB FRX COM LED PED LCK SET LOOP DETECTOR Figure 25 CP201 Trigger Connections Page 43 PILLAR LIGHT PUSHBUTTON HOLIDAY LOCKOUT KEYSWITCH PEDESTRIAN KEYSWITCH LOOP STATUS LED NO NC COM +12V IRB RECEIVER NEG IRB Tx REMOTE CONTROL CIRCUITRY 12V or 24V INFRA RED BEAM CIRCUITRY NO NC +12V/24V NEG COM RADIO RECEIVER FREE EXIT CIRCUITRY NO NC +12V/24V NEG COM MAX CURRENT 250mA PUSHBUTTON FOR SWITCHING PILLAR LIGHT (N/0) HOLIDAY LOCKOUT SWI
A10 Cable Routing FRO M DC OPTIO CON VER NAL TER SIG TO CNAL CA ONT BLE ROL LER TO P IL LIGH LAR TS FRO M MAI AC NS Figure 26 A10 Cable Routing Page 44
A10 Cable Interconnections CP200 R INVERTE SY COURTE PILLAR / NTIAL-FREE) E T O LIGHT (P X 400W) (MA AC 220-240V SE HA P E L G SIN L N E AL FAN OPTION l To optiona ter DC conver R ENCODE SENSOR ORIGIN SENSOR CP201 LLER CONTRO Figure 27 A10 Cable Interconnections Page 45
LED Indicator Lights The controller is fitted with diagnostic LEDs (Light Emitting Diodes) that assist with the setup and maintenance of the gate. Table 1 provides a description and purpose of the indicator LEDs. See Figure 23 and 25 for location.
Controller Functions FEATURE DESCRIPTION Gate Limit Settings STATUS or COUNT FEATURE NUMBER STATUS VALUE COUNT VALUE DESCRIPTION 1 - - See detailed instructions on page 30 1 - ON 2 - OFF (Default) - 1 Flash = 1 second 15 seconds (Default) 1 - STANDARD (Default) 2 - CONDOMINIUM 3 - PIRAC 4 - REVERSING 5 - PLC Autoclose 2 Autoclose Time 3 Mode of Operation 4 Pedestrian Auto-close 5 - 1 Flash = 1 second 5 seconds (Default) Courtesy Light 6 - 1 Flash = 10 seconds
FEATURE DESCRIPTION Closing sprint mode select STATUS or COUNT FEATURE NUMBER STATUS VALUE COUNT VALUE DESCRIPTION 14 Motor cutout time 15 Inverted Rack 16 1 - Standard speed (Default) 2 - Standard speed + 30% 3 - Standard speed + 60% 4 - Standard speed + 90% - 1 Flash = 1 second 60 seconds (Default) 1 - Rack below pinion 2 - Rack above pinion (Default) Table 2 continued Controller Functions Menus and Submenus Installation Handover Once the installation has been successfull
5. Secure all easily accessed gate opener controls in order to prevent unauthorized use of the gate. 6. Keep the automated gate system properly maintained, and ensure that all working areas are free of debris and other effects that could compromise the gate operation and safety. 7. On a monthly basis, check the obstruction detection system, and safety devices for correct operation. 8. All repair, and service work to this product must be done by a suitably qualified person. 9.
Notes Page 50
Notes Page 51
Sharecall 0860-CENTURION (0860 236 887) Head Office: +27 11 699 2400 Sharecall Technical Support 0861 003 123 or +27 11 699 2481 from 07h00 to 18h00 (GMT+2) (Sharecall numbers applicable when dialed from within South Africa only) 0.07.A.0067_22072013 www.centsys.
