R3 and R5 installation manual TM TM ROTARY SWING GATE OPERATOR
Company Profile CENTURION SYSTEMS has been manufacturing automatic gate systems since 1987, and is committed to providing reliable, cost effective solutions in the field of access automation. CENTURION strives to give service and backup second to none. Our engineers are available to give sales support, installation training, and answers to technical or installation problems. The equipment is installed worldwide and is available through a network of distributors.
Table of Contents Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Important Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Fast Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 General Description . . . . . . . . . . . . .
Declaration of Conformity Manufacturer: Centurion Systems (Pty) Ltd Unit 13 Northlands Production Park Epsom Avenue Northriding Randburg Johannesburg 2196 Declares that the product: Product Name: R3/R5 Swing Gate Operator Product Options: All variants Conforms with the following specifications: Safety: IEC 60355-1:1991 & Am1:1994 & Am2:1999 Emissions: CISPR 22 CLASS B: RADIATED EMISSIONS - 30MHZ TO 1000MHZ CISPR 22 CLASS B: CONDUCTED EMISSIONS - 150MHZ TO 30MHZ Immunity: IEC 61000-4-2 - ELECTRO
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. Mechanical Setup Action Step 1 Read and understand all safety instructions Page 5 Step 2 Gather required tools and equipment. Page 12 Step 3 Heed necessary site considerations. Page 13 Step 4 Check cabling requirements.
Fast Track Electrical Setup Action Step 1 Read and understand all safety instructions Page 5 Step 2 Connect all wiring: Page 27 Step 3 Set the gate origin: Page 27 Release the manual override and close the gate(s) Use origin tool and line up marks Open gate ½ way and unscrew the manual release mechanism. Step 4 Get into programming mode: Page 28 Remove all power. Fit the SET link. Reapply power. Step 5 Select master or slave set-up: Page 29 Press and hold TEST, release after 1 flash of L1.
General Description The R3 & R5 rotary swing gate systems are designed to open and close swing gates. The CP75 controller is capable of handling both single and double swing gates and offers many features to suit almost any application. Detailed specifications for the R3 & R5 motors are shown in the figure below and the table alongside. The unit employs a battery driven DC motor for low duty domestic applications, which provides automatic backup protection in the event of a power failure.
SPECIFICATION Input Voltage* AC Current draw (with C84E Battery Charger) R3 R5 220V AC ±10% 50Hz 220V AC ±10% 50Hz 120mA 120mA DC Motor Voltage 12V 12V DC Current draw (Max) 30A 35A Maximum solenoid lock current draw 2A 2A 3.5 rpm 2.6 rpm 95Nm 250Nm Output shaft rotational speed Maximum output torque Mass of master motor kit (excluding pedestal or wall bracket) 14.4kg 15,5kg Mass of slave motor kit (excluding pedestal or wall bracket) 12.
SPECIFICATION (continued) Maximum gate length & mass for Installation: Standard Inward Opening or Limited Space Installation Maximum wind speeds for which the operator will open the gate: Gate Length: 1,5m 2,0m 2,5m 3,0m R3 - Max. Allowable Leaf Mass: R3: For a 1,8m high gate, 25% coverage#: R3: For a 1,8m high gate, 100% coverage#: 400kg 400kg 320kg 225kg 160kg 75km/h 37km/h 54km/h 27km/h 44km/h 22km/h 38km/h 19km/h 34km/h 17km/h R5 - Max.
1. 2.* 3. 4.* 5. 6.* 7. 8.* 9.* 10. 11. 12. Baseplate Battery (7 A/H) Geared DC Motor Master Controller (CP75) Slave Interface Card (CP75B) Controller Enclosure Gearbox Charger (CP84ER5V01) Enclosure Uprights Warning Decal Wall Mount Bracket (Version 2) Pedestal (Version 2) † Pedestal and wall mount installations require different connecting arms. Be sure to use the correct connecting arm for the particular installation type. * Not fitted to a slave motor in a double leaf gate system.
Required Tools & Equipment Electric Drilling Machine Spanners 22mm 17mm 13mm Crimping Tool and Pin Lugs Hammer 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 (see page 9). 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.
Cabling Requirements Mains isolator switch To dwelling LEGEND 1. 220V AC mains cable via mains isolator switch (3 core LNE 0,5mm2)*†, 4. Radio receiver cable (3 core 0,5mm2 multistranded). Or 5. Low voltage 16V AC battery charger supply (2 core 1,5mm2)†. Pedestrian key switch (if required) (2 core 0,5mm2 multistranded). 6. Infrared beams or safety edge (if required) (3 core 0,5mm2 multistranded) 7. Intercom cable (n2+2 core 0,5mm2 multistranded) to gate station. 2.
Operator Installation Wall Mount Installation (R3 operators only) Pedestal Mount Installation (R3 and R5 operators) Figure 6 Basic Installation Options Pedestal Mount Features Wall Mount Features Secure locking with no need for gate end stops. Very compact installation. Can be used on both inward and outward opening gates and on installations where space is limited. Requires a pillar strong enough to support the operator and potential loading if the gate is forced.
Where to Position the Operator PEDESTAL POSITIONING FOR STANDARD INSTALLATION (SMOOTHEST MOVEMENT, BEST LOCKING) C GATE LEAF IN CLOSED POSITION b 50mm # E B A# GATE LE AF IN OPEN 158 POSITIO N Pedestal BE SURE TO USE A ‘LONG’ CONNECTING ARM FOR THIS INSTALLATION TYPE.
PEDESTAL POSITIONING FOR INSTALLATIONS WITH LIMITED SPACE BE SURE TO USE A ‘LONG’ CONNECTING ARM FOR THIS INSTALLATION TYPE.
PEDESTAL POSITIONING FOR OUTWARD OPENING GATES It is recommended to fit end stops in the open position of the gate to reduce gate movement when open. o 120 o 110 o o o 100 90 80 70 o 60 o BE SURE TO USE A ‘LONG’ CONNECTING ARM FOR THIS INSTALLATION TYPE.
PERPENDICULAR WALL MOUNT FOR INSTALLATIONS WHERE THE GATE OPENS 90 O OR LESS FOR INSTALLATIONS WHERE THE GATE OPENS MORE THAN 90 O Wall Mount Bracket Wall Mount Bracket A# A# 90 o C C GATE LEAF IN CLOSED POSITION B GATE LEAF IN CLOSED POSITION b b # D 50mm D 50mm # B C D Gate Opening Angle (Degrees) Gate Centre to Bracket Centre Hinge Centre to Mounting Face Hinge Centre to Gate Bracket Drive Arm Length 60 70 80 90 100 110 120 140 to 180 (140) 180 to 220 (180) 180 to 260 (180) 170 t
PARALLEL WALL MOUNT FOR INSTALLATIONS WHERE THE GATE OPENS LESS THAN 90 O FOR INSTALLATIONS WHERE THE GATE OPENS MORE THAN 90 O b A# B C D Gate Opening Angle (Degrees) Gate Centre to Bracket Centre Hinge Centre to Mounting Face Hinge Centre to Gate Bracket Drive Arm Length 60 70 80 90 100 110 120 310 to 330 (310) 350 to 370 (350) 350 to 410 (350) 340 to 500 (380) 370 to 500 (400) 390 to 490 (430) 400 to 460 (440) 220 to 380 (340) 220 to 380 (340) 220 to 380 (300) 220 to 380 (300) 220 to 380 (3
Minimum 12mm to allow for drive arm clamp assembly GATE BRACKET LOCATION & PEDESTAL HEIGHT FOR PEDESTAL MOUNT INSTALLATION C (See Fig. 76 to 9) 8) 85mm 37mm Gate Bracket 500mm Cabling Pedestal Concrete 300mm² GATE & WALL BRACKET LOCATION FOR VERTICAL WALL MOUNT INSTALLATION Minimum 125mm to allow for drive arm clamp assembly 85mm 37mm Wall Bracket Gate Bracket C (See Fig.
2. Determine a suitable position for the pedestal or wall mount bracket using the swing angle and dimensions A and B as found in the tables in Fig 7 to 11. (Values given in BOLD indicate the recommended dimensions). Before finalising the position of the pedestal or wall bracket, see points 5 & 6 below. If it is not possible to find a suitable position within the given A and B dimensions, then contact your local Centurion Systems sales office. 3.
8. Securely concrete the pedestal into position making sure that it is vertical, and at the correct height relative to the gate bracket, as shown in Fig. 12. Allow concrete sufficient time to cure. In the case of a wall mount installation, securely fix the wall mount bracket in the determined position to the wall or pillar using four M12 Rawl bolts. Fasten Gearbox in Position 9. Fasten the motor onto the pedestal adaptor plate or wall bracket, as shown in Fig.
Gate le af in O L pen Pos ition Gate leaf in Closed Position Example: If L = 934 and S = 333 then D = 934 - 333 2 = 601 2 therefore D (drive arm length) = 300.5mm S (Do NOT cut the drive arm to this length allow an extra 50mm i.e. cut drive arm D = 350mm. See Fig. 16) The easiest way of measuring L and S is to hold the zero mark of the tape measure on the middle of the output shaft, and then to read off L and S at the gate bracket.
Inner tube 1 Twist anti-clockwise to loosen. Outer tube 2 Retract inner tube completely Apply each of the warning decals to both the inward and outward faces of the gate frame. Twist clockwise until ski-pole lock starts to tighten Figure 17 Prepare Connecting Arm For Installation Figure 18 Apply warning decals to gate until the ski-pole lock starts to tighten. Do not over tighten, as that will make the final adjustment more difficult. 14.
19. Once a satisfactory gate opening has been achieved, the connecting arm must be fully tightened: Disconnect the connecting arm from the gate bracket. Remove the bushes from the front end of the connecting arm. Using a large screwdriver or similar lever, tighten the ski-pole lock using halfturns until it is as tight as possible and aligned with the gate bracket. Replace the bushes and reconnect the connecting arm to the gate as shown in Fig. 19. 20.
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.
Setup Tool Manual Release Mechanism Figure 26 Fit Setup Tool into Release Mechanism Setup Tool Figure 25 Setup tool in stored position 8. Repeat the procedure for the other motor in a double swing system. 9. Return the origin tool to its storage position on the upright pillar and close the override dust cover. 10. With the gates still in manual mode, move the gates to the ½ way open position, and unscrew the manual release until the top of the screw is flush with the top of the shaft.
Select either Master or Slave motor setup TEST Pushbutton (The gate limits of the Master and Slave motors are set independently of each other.) 15. Press and hold the TEST button (Fig 29) down for 1 flash of L1, and then release. L2 will go off, and L1 will now be flashing once per second. 16. Again press and hold TEST button, but this time monitor the STATUS light.
by pressing, holding and releasing the test button, as in step 19 and 20. 21. Then press and release the TEST button once more to confirm the OPEN limit. When setting Master motor limits: When setting Slave motor limits: 22. The gate will close completely, pause and then open to the minimum pedestrian position. The gate will close slightly. The STATUS light will flash 5 times, and L2 will come on, to indicate that the limits were set.
(See Set-up Troubleshooting Guide step 14 or 29) Selecting the Feature to Change (This is the first of two steps in setting a Feature. This only SELECTS the feature to change). 30. To select the Feature to change, Press and hold the TEST button while monitoring L1. 31. L1 will flash once then go off, twice in short succession then go off, 3 times then go off, etc. Release the TEST button when the number of flashes is the same as the Feature number to select.
L2 will come back on, indicating that the STATUS has been updated. 34. To set the COUNT value of the Auto-close timer, Pedestrian Auto-close time, Courtesy light timer, Auto-close override timer, Pre-flashing time, Collision counter, or the Leaf delay time Features: Press and hold the TEST button while monitoring the STATUS light. After a slight pause, the STATUS light will start flashing at an even rate.
impulse while the gate is still moving will stop the gate. A third impulse will cause the gate to reverse its direction of travel, i.e. the action is START - STOP - REVERSE. CONDIMINIUM 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 auto-close will automatically be turned on when condominium mode is selected. It is only the auto-close signal, which can close a gate in condominium mode.
• When the PED input is triggered the pillar light flashes for an adjustable (1 to 255 seconds) preflash time (FEATURE 11 - COUNT) before the pedestrian gate opens. (Default pre-f;ash time is 2 seconds). • The contact can be used to operate a lamp, which will warn that the gate is about to open. Selection of pre-flashing is done in FEATURE 10. Three modes and OFF are selectable (The factory default is OFF): Mode 1 - Light comes on only while gates are in motion.
Set-up Troubleshooting Guide SET-UP STEP 14 or 29 PROBLEM POSSIBLE CAUSES & SOLUTIONS TO PROBLEM SET light is not on: Check that the SET link is correctly fitted. Fit and remove the link a few times to ensure good contact. L2 is not on: All sources of power on the card must be removed. Check by confirming that all the lights turn off, before reconnecting the power with the set link fitted. STATUS light did not flash 5 times: The controller did not “boot-up” correctly.
Set-up Troubleshooting Guide Continued... 17 (continued) Motor briefly starts and The battery is not connected. Correct the problem, remove and then stops, and STATUS refit the SET link and start from step 17. Faulty DOSS sensor or cable. flashes 5 times. Motor starts then stops The DOSS sensor system is faulty. Is the DOSS harness after 1 second (STATUS plugged in? If so, there could be a fault on the sensor, cable or controller.
Set-up Troubleshooting Guide Continued... 24 (continued) Positive close mode has been activated. Deactivate positive The motors keep on driving past the closed close mode by setting feature 9 to 1. position: The slave gate runs slower than the master gate: The slave motor cables are too thin, ensure that the cables are at least 2.5mm² The gate starts and then The installation geometry does not give the motor enough stops moving when gate mechanical advantage to get the gate started.
Fault Finding Guide Continued... PROBLEM 2 3 4 Gate does not move, but the relays “click” when the unit is activated: POSSIBLE CAUSES & SOLUTIONS TO PROBLEM Check that you are out of programming mode, SET light must be OFF. Check the battery condition with procedure A: Low battery voltage condition, later in this section. Check the motor wires. If STATUS light flashes 4 times then the operator is in Multiple Collision Mode.
Fault Finding Guide Continued... PROBLEM 5 6 7 Gate overruns its limits: Gate opens on its own Unreliable auto-close POSSIBLE CAUSES & SOLUTIONS TO PROBLEM Check for intermittent IRB (IR Beam) triggers. (Check beam operation, alignment and supply voltage). Intermittent/spurious signal on FRX or TRG if in CONDO,. PIRAC or REVERSING modes. (Standard mode would first stop then reverse) If the problem is still not solved, the CP75 main controller might be faulty.
Fault Finding Guide Continued... PROBLEM 8 9 Gate opens to pedestrian and closes Gate takes a few seconds before it opens to pedestrian 10 Gate opens to pedestrian & stays there POSSIBLE CAUSES & SOLUTIONS TO PROBLEM Long pulse on TRG would activate the auto-close override feature. Faulty IR Beam input. Intermittent power loss, check for low voltages with procedure A: Low battery voltage condition. If the problem is still not solved, the CP75 main controller might be faulty.
Fault Finding Guide Continued... PROBLEM A POSSIBLE CAUSES & SOLUTIONS TO PROBLEM Low Battery (If the battery voltage is less than 10.5V, the motor would not Voltage Condition operate at all. For any other voltage, the battery could still be the (STATUS light flashes 3 times) cause of the problem. Check that the power is turned ON, by first disconnecting the battery and then to check that the green CHARGE light is ON. If it is OFF, then power is not connected to the charger or the power pack.
Fault Finding Guide Continued... PROBLEM B False Collision Detection (STATUS light could flash 4 times to indicate that number of collisions have exceeded COLLISION COUNTER feature value. Wait 60 seconds, or remove & reapply all power to reset operation.) POSSIBLE CAUSES & SOLUTIONS TO PROBLEM To determine which is the faulty gate in a double swing system, activate the gates. Both gates will stop and reverse on closing, but only the faulty gate will stop when opening.
Procedure to Programme Controller Back to Factory Default Settings 1. Remove all power (Power supply and battery ). 2. Fit the "SET" link. 3. Connect "PED" and "FRX" to "COM". 4. Reconnect all power. (L1 AND L2 will illuminate). 5. Remove all power (Battery and power supply). 6. Remove the "SET" link and disconnect "PED" and "FRX" from "COM". 7. The card is now programmed to default settings as shown in table 2 (see page 47) (Gate end points are not affected).
Determine Gate Swing Angle Use this procedure to accurately determine the gate opening angle: Step 1 Close the gate and measure a distance of 1m from the gate hinge. Make a mark on the ground. 1m Step 2 Open the gate and measure a distance along the gate a distance of 1m from the gate hinge. Make a mark on the ground. Measure the distance on the ground between the two marks (Z). Using this Z value, read off the gate opening angle from the table below. Step 3 1m Z GATE SWING ANGLE VALUE Z FROM...
Description of Terminal Functions MASTER The master motor is connected to these terminals. If the master motor direction is incorrect swap around the wires connected to these terminals. SLAVE The slave motor (in dual swing gate applications) is connected to these terminals. As with MASTER, swap the connected wires around for motor direction reversal. COM The battery/power supply negative terminal. All trigger signals etc. have their return path to one of the COM terminals.
LED Indicator Lights The controller is fitted with diagnostic lights (LEDs) that assist with the set-up and maintenance of the gate. Table 1 provides a description and purpose of the indicator lights. Refer to page 46 for location.
CP75 Controller Functions FEATURE STATUS or COUNT DESCRIPTION FEATURE NUMBER STATUS VALUE COUNT VALUE DESCRIPTION Gate Limit Settings 1 - - See detailed instructions on page 29 2 1 - ON Auto-close 2 - OFF (Default) - 1 Flash = 1 second 15 seconds (Default) 1 - STANDARD (Default) 2 - CONDOMINIUM 3 - PIRAC 4 - REVERSING 5 - 1 Flash = 1 second 5 seconds (Default) 6 - 1 Flash = 10 seconds 120 seconds (Default) 1 - HIGH (Default) 2 - MEDIUM 3 - LOW - 1 Flash =
6-WAY CONNECTOR CP75 Controller Connections 1 2 3 4 FOR DETAILED CONNECTIONS, REFER TO CP 75 CONTROLLER TRIGGER WIRING ON PAGE 47 M LIVE 220V AC MAINS IN L N E RED / BLACK / ORANGE AUXILIARY SUPPLY RED / BLACK / PURPLE NEUTRAL 3-WAY CONNECTOR 3-WAY CONNECTOR TO ORIGIN SENSOR ON MASTER MOTOR TO COUNTER SENSOR ON MASTER MOTOR CP84ER5V01 NOTE: WHEN SETTING THE GATE LIMITS DURING THE COMMISSIONING PROCEDURE AS DESCRIBED ON PAGE 29, IT MAY BE NECESSARY TO CHANGE THE MOTOR DIRECTION.
CP75 Trigger Connections For a detailed description of terminal functions, refer to DESCRIPTION OF TERMINAL FUNCTIONS on page 45.
CP84ER5V01 Charger Connection L N E 1 CP84ER5V01 Charger Transformer 2 14.
Installation Handover Once the installation has been successfully completed and tested, it is important for the installer to explain the operation and safety requirements of the system. NEVER ASSUME THE USER KNOWS HOW TO SAFELY OPERATE AN AUTOMATED GATE. Even if the user has used one before, it does not mean he knows how to SAFELY operate it. Make sure that the user fully understands the following safety requirements before finally handing over the site.
Installation Details Installation Date: Installer's Name: Installer's Address: Installation Checked By: Installer's Telephone Number: Page 52
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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.0058_22072013 www.centsys.
