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

TEL: 0115 921 0430FAX: 0115 921 0431

INTERNET - www.cameuk.com E-MAIL - enquiries@cameuk.com

TECHNICALHELPLINE

0115 921 0430

GARD G6000Installation Instructions

for swift road barriers

THE GARD KIT CONSISTS OF:

BARRIER UNITCONTROL PANELALUMINIUM BARRIER ARMRED PHOSPHORESCENT STICKERSSAFETY BEAM POSTSAFETY BEAM

INTRODUCTIONTHESE INSTRUCTIONS WILL SHOW YOU HOW TO INSTALL AGARD 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.

1

GENERAL SPECIFICATION

DESCRIPTION:

This unit can be used to control entrances up to 6.5 metres wide (with accessories on the barrier upto 6metres). Designed and constructed by CAME in compliance with current safety standards (UNI8612) 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 controlcircuit 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 recommendinstallation of CAME safety and control accessories.

2

TECHNICAL CHARACTERISTICS

EXTERNAL DIMENSIONS

TYPE WEIGHT POWER CURRENT MOTOR DUTY REDUCTION MAX TIMEKG SUPPLY DRAW POWER CYCLE RATIO TORQUE

G6000 230V AC 1.3A-230V 300W HEAVYG6001 72 24V DC 15A-24V DUTY 1/202 600Nm 4-8s

3

450

460 240

914

= =

1077

295

TECHNICAL DESCRIPTIONA 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.

B Mounting base in galvanised steel with anchor stays and bolts for anchoring the case to thebaseplate.

C The flange is in galvanised steel. This holder allows the barrier to be quickly and securely locked.

D Manual release system.

E Motor: 24V DC reduction gear, non-reversible with die-cast aluminium housing and ispermanently lubricated with liquid grease.

F A spring acts as counterbalance for precise uniform movement.

G An internal shock absorber/travel stop is provided.

H Limit switch assembly.

I Control panel (ZL37F)

4

#

$

%

Technic l descriptionTechnic l descriptionTechnic l descriptionTechnic l descriptionTechnic l description

C

DE

A

I

F

L

B

G

H

INSTALLATIONConstruct 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 mustbe perfectly level and clean from end to end. All screw threads must be completely accessible fromthe 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 dooron the inside of the property. Tighten the unit down and check for level. Fit the barrier arm and adjustthe mechanical stops to stop the arm in the desired position.

5

Cable exit

Mounting base for case

380

140

240

460

B C

A

COMMISSIONING1. 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 thefour allen screws provided. Adjust the mechanical stops B and C to obtain the desired vertical andhorizontal positions. (see figure 1)

B C

A

6

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

L

L

B

A

L

7

L m <4 <5 <6 <6.5Spring 1A 1A 1B 1A

Positions 1B

L m <4 <5 <6Spring 1A 1B 1A

Position 1B

SpringattachmentPoints

With skirts orMobile support

L m <4 <5 <6Spring 1B 1A 2B

Position 1B

4. Unlock the gearmotor and change the position of the springs (do not throw away the spring if notused)

5. The barrier arm should be balanced at 45º 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

45º.4) Now tighten the locknuts and re engage the gear motor by using the manual release key.

8

200

max

80 m

ax

A

B

6) Connect mains power to terminals L1 and L2 and connect to a suitable earth.7) 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 commissioning10) Set the Transformer as follows for commissioning: - SPEED to minimum and DECLERATION to

minimum.

To set the speed and deceleration, move the faston connectors “A” and “B” onto the indicatedterminals

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.

9

Deceleration

Max Min Min Med Max

COM

Speed

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

TRIMMER SENS

15) If automatic closing is required move dipswitch 1 to the on position and adjust potentiometer TCAuntil the desired time is achieved.

16) If safety beams or induction loops are used to prevent the barrier closing onto vehicles, removethe 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 2and move dipswitch 9 to the OFF position.

18) If a closed only button is required move the jump strap that is positioned between the terminalblocks 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 facilityby moving dipswitch 10 to the OFF position.

10

TROUBLE SHOOTINGFault Action

Barrier goes up but will not go down 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.

The barrier stalls when moving up or down Check that the barrier is balanced at the 45∞whenthe barrier is manually released.Check that the barrier sensitivity is set correctly and adjust accordingly.(minimum sensitivity gives you maximum power)

The barrier arm stalls when a Check all of the aboveshort arm is fitted Check that the increased braking facility has not

been used (dipswitch 10)

TECHNICAL HELP LINE

0115 9210430

11

12

TECHNICAL DESCRIPTION OF ZL37FCONTROL PANEL

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

SAFETYPhotocells 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: seeNOTE;- Fixed operating time of 20 sec.

OTHER FUNCTIONS- Automatic closing: The automatic closing timer is automatically activated at the end of the openingcycle. The preset, adjustable automatic closing time is automatically interrupted by the activation ofany 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 remotecontrol system is deactivated);- Obstacle detection: When the motor is stopped (bar is closed, open or half-open after anemergency stop command), the transmitter and the control pushbutton will be deactivated if anobstacle 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 turnsoff 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 instructionsheet);

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

13

ZL37F MOTHERBOARD

MAIN COMPONENTS1 Terminal block for external connections2 3.15A line fuse3 2A accessories fuse4 "Function selection" dip-switch5 Radiofrequency board socket (see table)6 TCA trimmer: automatic closing time adjustment7 SENS trimmer: amperometric sensitivity adjustment8 Button for memorizing code numbers9 Radio code / automatic closing signal LED10 Connectors for power supply motor11 Connectors for connection to battery charger (LB35)12 Jumper for selection of type of control for button in 2-7

21 3 4 5 6 7 8 9 10

ZL 37QU ADRO CO MANDO

PTL2TL1T

M

"A""B"

Max.Med.Min.Min.Max.

14

DIPSWITCH SELECTION OF FUNCTIONS

1 ON Automatic closure enabled;

2 ON "Only open" radio control or pushbutton function enabled (with plug-in radiofrequencyboard);

2 OFF "Open-close-reverse" radio control or pushbutton function enabled (with plug-in radiofrequency board);

3 ON 24V output voltage on 10-E terminals when the barrier is in motion and in the barrier'sclosed position, enabled;

3 OFF 24V output voltage on 10-E terminals when the barrier is in motion, enabled;

4 ON "Operator present" function enabled;

5 ON Pre-flashing (aperture and closure) enabled;

6 ON Obstacle detection device (motor of limit position) enabled;

7 ON "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;

1ON 2 3 4 5 6 7 8 9 10

21 3 4 5 6 7 8 9 10

0

Rall.

Vel.

7 4ZL 37QU ADRO CO M ANDO

PTL2TL1TL2L1

ONOFF

15

PROGRAMMING THE REMOTE CONTROLST432S (MINI-PINK) Remotes

Remove the battery cover off of the remote and change the Factory set code to a unique code for theinstallation via the 10 dipswitches.

Insert the frequency card into the control panel (item 5 on motherboard). Identify the little yellow buttonon the motherboard and press and hold the little yellow button in and an LED will flash. Then pressthe button on the remote control you wish to operate the equipment with and then let go of bothbuttons. Make sure any additional remotes are the same code. You do not have to program these intothe board - they should work.

OFFON

1

3

MOTHERBOARD

"AF" BOARD

NS. -

- T.C.A. -

1ON 2 3 4 5 6 7 8 9 10

Channel 1

Channel 3

Channelsselectionjumpers

Code selectiondipswitch:set the samecodeprogrammedon receiver

actionning LED

4 pins strip

1st key fixedon channel 1

2nd key preset onchannel 2; put thejumpers as shown infigures to change

Channel 4

Channel 2

Channels Scheme

16

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)

2. Within 10 seconds, bring the existing transmittercloser from the rear part and press the pushbutton youwant 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.

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

Use on new systemConsult the documentation of the electric board to save the first transmitter, then follow the proceduredescribed above to duplicate it in the quantity desired.

To open battery compartment, press and slide.

A

B

Red signalling LED

17

ZL37FELECTRICAL CONNECTIONS

230V (a.c.) power supply

24V (d.c.) motor

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

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

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.)

Pushbutton stop (N.C.)

10

E

L1

L2

N.B. When connecting thephotocells (TX and RX),observe the correctpolarities.

1010 1111

RX

NO C NC

TX

10

11

M

N

10

5

1

2

FA FC F PTE +10-11 1 2 C1C573 5 INTERBLOCCO M N

during movement (e.g. flashing light)

24V output

during movement and in the closed position

DIP 3OFF

DIP 3ON

18

ZL37FELECTRICAL CONNECTIONS

Open pushbutton (N.O.)

Collegamento radio e/o pulsante (N.O.)per tipo comando, vedi dip-switch 2Connector (N.O.) radio and/or pushbuttonsee dip-switch 2 for command typeConnection radio et/ou bouton-poussoir (N.O.)pour commande voir dip-switch 2Anschlufl Funkkontakt und/oder Taste (N.O.)Steuerart siehe dip-switch 2ConexiÛn radio y/o pulsador (N.O.)para mando mirar dip-switch 2

Contact (N.C.) for ´ re-aperture during closureª

Contact (N.C.) of ´ immediate closureª

Connection microswitch deceleration opens

Connection microswitch deceleration closes

Antenna connection

2

C1

F

FA

F

FC

2

C5

2

7

2

3

E 10 11 1 2 3 5 7 C1 C5

2-C1

dip 8 ON

Connector (N.O.) radio and/or pushbutton. See DIP 2 for command type

Button operation: closure only

JUMPER

JUMPER

if not used

if not used

19

ZL37BARRIER SPEED ADJUSTMENT

To set the barrier speed and deceleration, move the faston connectors “A”+”B” onto the indicatedterminals

COM

B A

DECELSPEED

ARMSPEED

Max Min Min Med Max

CONNECTION FOR TWO COMBINED MOTORSCONTROLLED TOGETHER

1) On one of the two controlpanels, set Dip 7 to ON in orderto select the motor controlledexternally (slave).

2) Wire the electricalconnections only on theterminal board for the pilotmotor in the normal.

3) Connect the two controlpanels using the interlockterminals as shown in thefigure.

Speed

Vi tes se

Velocidad

Decelera tion

Ralentissemen t

DeceleraciÛn

0

Rall.

Ve l.PTL2TL1TL2L1

"B" "A"

Speed

Vi tes se

Velocidad

Decelera tion

Ralentissemen t

DeceleraciÛn

0

Rall.

Ve l.PTL2TL1TL2L1

"B" "A"

CAME

SX DX

Speed

Vi tes se

Velocidad

Decelerati on

Ralent iss ement

DeceleraciÛn

0

Rall.

Ve l.PTL2TL1TL2L1

"B" "A"

Sp e dVi tes se

Ve loc ida d

D ece ler atio n

Ra len tis sem en t

D ece ler aciÛ n

0

R al .

V el.

"B " "A "

Sp

ee

d

Vi tes se

Velocid

ad

Decelera tion

Ralentissemen t

DeceleraciÛn

0

Rall.

Ve l.PTL2TL1TL2L1

"B" "A"

Sp

ee

d

Vi tes se

Velocid

ad

Decelera tion

Ralentissemen t

DeceleraciÛn

0

Rall.

Ve l.PTL2TL1TL2L1

"B" "A"

Speed

Vi tes se

Velocidad

Decelerati on

Ralent iss ement

DeceleraciÛn

0

Rall.

Ve l.PTL2TL1TL2L1

"B" "A"

1)

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

Sp e dVe loc it‡Vi tes seG esc hw .Ve loc ida d

D ece ler atio nRa lle nta me ntoRa len tis sem en tG esc hw .Ab na hm eD ece ler aciÛ n

0

R al .

V el.

7 4Z L 3 7

"B " "A "

lin e fu se

m o tor fu s ea cc es so ri es fu se

Slave motor 2∞ control panel

Sp

ee

d

Vi tes se

Velocid

ad

Decelera tion

Ralentissemen t

DeceleraciÛn

0

Rall.

Ve l.PTL2TL1TL2L1

"B" "A"

Sp

ee

d

Vi tes se

Velocid

ad

Decelera tion

Ralentissemen t

DeceleraciÛn

0

Rall.

Ve l.PTL2TL1TL2L1

"B" "A"

COM Max.Med.Min.Min.Max.

SpeedVe locit‡Vi tes seGeschw.Velocidad

Decelerati onRallentamentoRalent iss ementGeschw.Ab nahmeDeceleraciÛn

21 3 4 5 6 7 8 9 1 0

0

Rall.

Ve l.

7 4ZL 37CON TR OL P ANEL

PTL2TL1TL2L1

"B" "A"

line fuse

motor fuseaccessories fuse

FA FC F PTE +10-11 1 2 C1C573 5 INTERBLOCCO M N

2)

(pilot) motor 1∞ terminal block

Sp e dVi tes se

Ve loc ida d

D ece ler atio n

Ra len tis sem en t

D ece ler aciÛ n

0

R al .

V el.

"B " "A "

COM Max.Med.Min.Min.Max.

SpeeeedVe locit‡Vi tes seGeschw.Velocidadad

Decelera tionRal lentamentoRalentissemen tGeschw.AbnahmeDeceleraciÛn

21 3 4 5 6 7 8 9 10

0

Rall.

Ve l.

7 4ZL 37CON TROL P ANE L

PTL2TL1TL2L1

"B" "A"

line fuse

motor fuseaccessories fuse

COM Max.Med.Min.Min.Max.

SpeeeedVe locit‡Vi tes seGeschw.Velocidadad

Decelera tionRal lentamentoRalentissemen tGeschw.AbnahmeDeceleraciÛn

21 3 4 5 6 7 8 9 10

0

Rall.

Ve l.

7 4ZL 37CON TROL P ANE L

PTL2TL1TL2L1

"B" "A"

line fuse

motor fuseaccessories fuse

FA FC F PT2 C1C573 5 INTERBLOCCO M N E +10-11 1 2 C1C573 5 INTERBLOCCO

3)

Slave motor 2∞ terminal block(pilot) motor 1∞ terminal block

Speed

Vi tes se

Velocidad

Decelerati on

Ralent iss ement

DeceleraciÛn

0

Rall.

Ve l.PTL2TL1TL2L1

"B" "A"

Sp e dVi tes se

Ve loc ida d

D ece ler atio n

Ra len tis sem en t

D ece ler aciÛ n

0

R al .

V el.

"B " "A "

20

21

HANDING THE G6000 BARRIER

SX = With the barrier arm on the outside and the cabinet facing the inside of the property. This unit isusually positioned on the left.

DX = With barrier arm on the outside and the cabinet facing the inside of the property. This unit isusually positioned on the right.

OUTSIDE

INSIDE

SX DX

IF THERE ARE ANY PROBLEMS PLEASE CONTACT THE CAMETECHNICAL HELPLINE:

0115 921 0430

22

NOTES

CONTACT INFORMATION

CAME UNITED KINGDOM LTD

UNIT 3ORCHARD PARK INDUSTRIAL ESTATE

TOWN STREET, SANDIACRE, NOTTINGHAM NG10 5BP

TEL: 0115 921 0430FAX: 0115 921 0431

INTERNET : www.cameuk.comE-MAIL: enquiries@cameuk.com

THIS INSTALLATION WAS COMPLETED BY:.........................................................................NAME..............................................................ADDRESS...................................................................................................................................................................................................................................................................................TEL........................ MOBILE............................DATE OF INSTALLATION................................