CENTURION SYSTEMS D 10 Installation Manual

SLIDING GATE OPERATORS
D10 SMART / D10 TURBO SMART /
D20 SMART
INSTALLATION MANUAL
Centurion Systems (Pty) Ltd
www.centsys.com
Company Profile
1986
1990
1995
In-house
R&D
development
team
1999
Today
Manufactures to
international
quality standard
ISO 9001:2015
ISO 9001:2015
After-sales
multi-language
Technical Support
100%
testing of
products
Sales and technical support
to Africa, Europe, Asia,
the Americas, Australia
and the Pacific
Call Centre Operating Times
Monday to Friday
07h00 to 18h00 GMT+2,
Saturdays
08h00 to 16h30 GMT+2
Centurion Systems (Pty) Ltd reserves the right to make changes to the product described in this
manual without notice and without obligation to notify any persons of any such revisions or changes.
Additionally, Centurion Systems (Pty) Ltd makes no representations or warranties with respect to
this manual. No part of this document may be copied, stored in a retrieval system or transmitted in any
form or by any means electronic, mechanical, optical or photographic, without the express prior written
consent of Centurion Systems (Pty) Ltd.
Contents
1.
INTRODUCTION
Page 5
1.1.
Important Safety Information
Page 6
1.2.
Lightning Protection
Page 8
1.3.
Theft Protection
Page 8
2.
SPECIFICATIONS
Page 9
2.1.
Physical Dimensions
Page 9
2.2.
Technical Specifications
Page 9
3.
PRODUCT IDENTIFICATION
Page 11
4.
REQUIRED TOOLS AND EQUIPMENT
Page 12
5.
NEW SITE INSTALLATION PREPARATION
Page 13
5.1.
General Considerations for the Installation
Page 13
5.2.
Endstops
Page 14
5.3.
Guide-rollers and Anti-lift Brackets
Page 14
5.4.
Starting and Running Forces
Page 15
5.5.
Cabling Requirements
Page 16
6.
LUBRICATION
Page 17
7.
OPERATOR INSTALLATION
Page 18
7.1.
New Site Installations
Page 18
7.1.1.
Locating an Initial Reference Point
Page 18
7.1.2.
Minimum Clearances
Page 19
7.1.3.
Locate the Operator's Position
Page 20
7.1.4.
Foundation Plate Installation
Page 24
7.2.
Retro-fit Installations (Existing Sites)
Page 25
7.3.
Conduit and Cable Length
Page 26
7.4.
Preparing the Operator for Installation
Page 26
7.4.1.
Removing the Charger
Page 27
7.4.2.
Removing the Gearbox Trim and Battery Tray assembly
Page 28
7.4.3.
Removing the Control Card
Page 29
7.5.
Mounting the Gearbox
Page 30
7.6.
Routing the Cables
Page 31
7.7.
Manual Override
Page 32
page 3
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CONTENTS
Height Adjustment
Page 33
7.9.
Mounting the Rack
Page 34
7.9.1.
Fitting Steel Rack to the Gate
Page 35
7.9.2.
Finalising the Height Adjustment
Page 35
7.9.3.
Placing the Gearbox Mounting Washers, Spring Washers and Lock Nuts
Page 37
7.8.
7.10. Re-assembling the Operator
Page 37
7.10.1. Placing the Gearbox Trim and Charger back into Position
Page 37
7.10.2. Placing the Control Card back into Position
Page 38
7.10.3. Reconnecting the Harnesses to the Control Card and Charger
Page 39
7.11. Installing the Origin Sensor and Marker
Page 40
7.11.1. Installing the Origin Sensor
Page 40
7.11.2. Mounting the Origin Marker
Page 41
7.11.3. Mounting the Origin Marker onto the Steel Rack
Page 42
8.
COMPLETING THE INSTALLATION
Page 43
8.1.
Fitting the Batteries
Page 43
8.2.
Accessory Installation and Storage
Page 44
8.3.
Wiring the Control Card on its Default Settings
Page 45
8.3.1.
Closing Infrared Beam Wiring (i5 Infrared Beams)
Page 45
8.3.2.
Closing Infrared Beam Wiring (Photon Infrared Beams)
Page 46
8.3.3.
External Radio Receiver and Loop Detector Wiring
Page 47
8.3.4.
G-ULTRA to D10 SMART / D10 Turbo SMART / D20 SMART Wiring
Page 48
8.4.
Commissioning the System
Page 48
8.5.
Apply Warning Decal
Page 49
9.
GENERAL MAINTENANCE
Page 50
9.1.
Gate Maintenance
Page 50
9.2.
D10 SMART / D10 Turbo SMART / D20 SMART Maintenance
Page 51
10.
INSTALLATION HANDOVER
Page 52
11.
WARRANTY INFORMATION
Page 53
Icons used in this manual
This icon indicates tips and other information that could be useful during the
installation.
This icon denotes variations and other aspects that should be considered during
installation.
This icon indicates warning, caution or attention! Please take special
note of critical aspects that MUST be adhered to in order to prevent
injury.
page 4
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SECTION 1
INTRODUCTION
1. Introduction
The D10 SMART is a heavy duty sliding gate operator designed to open and close industrial
sliding gates weighing up to 1000Kg.
The D10 Turbo SMART is perfectly suited for sites with lighter gates requiring a high
number of operations per day, and can reach almost double the speed of the standard
D10 SMART for increased security. However, it is not suitable for gates weighing more than
250kg, as the inertia generated by heavier loads might prove detrimental to the gearbox
at such high speeds. Refer to Table 2 under Section 2.2. - "Technical Specifications" for
derating speeds on heavier gates.
A die-cast aluminium gearbox, coupled to a powerful 24V DC motor and switch-mode
charger, makes the D10 SMART / D10 Turbo SMART the automatic choice for townhouse
complexes and office parks.
The system operates off two 12V / 7.2 - 8Ah batteries housed inside the operator using a
switch-mode charger to maintain the battery in a fully-charged state. The batteries provide
critical power failure protection.
A non-contact Hall Effect Sensor ensures reliability and positional accuracy. The Hall Effect
Sensor is highly resistant to dust, oil, dirt and insect ingress, thereby ensuring that the D10
SMART / D10 Turbo SMART opens and closes gates reliably and accurately.
For industrial sites with large, heavy gates and high traffic volumes, the D20 SMART offers a
powerful and reliable automation solution that can move gates weighing up to 2000kg.
This formidable operator has been designed to withstand the most demanding operating
conditions and work dependably in any environment thanks to its rugged die-cast aluminium
gearbox and potent DC motor. In addition, its sophisticated electronics and motor control
circuitry ensure that it moves smoothly with pinpoint stopping, further adding to the unit’s
reliability and longevity. Complementing its tough mechanical build, award-winning SMART
technology makes the D20 SMART as intelligent as it is solid.
Advanced features of the D10 SMART / D10 Turbo SMART / D20 SMART logic
controller include:
•
Interactive graphic user interface via a smartphone application
•
Automated setup of gate endpoints (limits)
•
Independently-adjustable motor speed in both opening and closing directions
•
Fail-safe collision detection and auto reverse (adjustable sensitivity)
•
Smooth, adjustable start/stop (ramp-up/ramp-down)
•
Multiple operational modes
•
Selectable, adjustable Autoclose
•
Pedestrian (partial) opening
•
Positive Close Mode
•
Independent safety inputs for opening and closing beams
•
Automatic beam test for both opening and closing beams
•
Advanced lightning/surge protection
•
Onboard NOVA code-hopping radio receiver with full channel-mapping capability
(Limited to 1500 NOVA remotes with multiple buttons per remote)
page 5
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SECTION 1
INTRODUCTION
1.1. Important Safety Information
ATTENTION!
To ensure the safety of people and possessions, it is important that
you read all of 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 who can ensure that the operator is safely installed and that
the whole system can be operated safely.
Warnings for the Installer
CAREFULLY READ AND FOLLOW ALL INSTRUCTIONS before installing the
product.
•
All installation, repair, and service work to this product must be carried out by a
suitably-qualified person
•
This appliance is not intended for use by persons (including children) with reduced
physical, sensory or mental capabilities, or lack of experience and knowledge, unless
they have been given supervision or instruction concerning use of the appliance by a
person responsible for their safety
•
Do not activate your gate unless it is in view and you can determine that its area of
travel is clear of people, pets, or other obstructions
•
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
•
Secure all easily-accessed gate opener controls in order to prevent unauthorised use
of the gate
•
Do not in any way modify the components of the automated system
•
Do not install the equipment in an explosive atmosphere: the presence of flammable
gases or fumes is a serious danger to safety
•
Before attempting any work on the system, turn off 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 hydraulic
breaker with all-pole circuit breaker is recommended
•
Make sure that an earth leakage circuit breaker with a threshold of 30mA is fitted
upstream of the system
•
Never short-circuit the battery and do not attempt to recharge the batteries with
power supply units other than that supplied with the product, or manufactured by
Centurion Systems (Pty) Ltd
page 6
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SECTION 1
INTRODUCTION
•
Make sure that the earthing system is correctly constructed and that all metal parts of
the system are suitably earthed
•
Safety devices must be fitted to the installation to guard against mechanical
movement risks such as crushing, dragging and shearing
•
Always fit the warning signs visibly to the inside and outside of the gate
•
The installer must explain and demonstrate the manual operation of the gate in case
of an emergency and must hand over the User Guide/Warnings to the user
•
The installer must explain these safety instructions to all persons authorised to use
this gate, 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 packing materials, worn-out batteries, etc.,
according to local regulations
•
Always check the obstruction detection system, and safety devices for correct
operation
•
Neither Centurion Systems (Pty) Ltd, nor its subsidiaries, accepts any liability caused
by improper use of the product, or for use other than that for which the automated
system was intended
•
This product was designed and built strictly for the use indicated in this
documentation; any other use, not expressly indicated here, could compromise the
service life/operation of the product and/or be a source of danger
•
Everything not expressly specified in these instructions is not permitted
WARNING! WARNING! WARNING! WARNING! WARNING!
KEEP CLEAR!
GATE MAY MOVE AT ANY TIME!
SAFETY
FIRST
MOVING GATE CAN CAUSE SERIOUS INJURY OR DEATH!
KEEP CLEAR! GATE MAY MOVE AT ANY TIME!
DO NOT ALLOW CHILDREN TO OPERATE THE GATE OR PLAY IN THE
NEAR VICINITY OF THE GATE.
page 7
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SECTION 1
INTRODUCTION
1.2. Lightning Protection
The electronic controller utilises the same proven surge protection philosophy that is
used in all our products. While this does not guarantee that the unit will not be damaged
in the event of a lightning strike or power surge, it greatly reduces the likelihood of such
damage occurring. The earth return for the surge protection is provided via the mains
power supply earth and/or earth spike located next to the operator.
In order to ensure that the surge protection is effective, it is essential
that the unit is properly earthed.
1.3. Theft Protection
While care has been taken in the design of the D10 SMART / D10 Turbo SMART /
D20 SMART to prevent unauthorised removal (theft) of the unit, an optional steel theftdeterrent cage is also available for added peace of mind. In addition, the system boasts
novel theft and break-in protection via an integral vibration sensor that can be connected
to a sound bomb or third party alarm system, or linked to an armed response company.
If a theft-deterrent cage is required, be sure to leave enough clearance from
pillars, etc. (Section 7.1.2. - "Minimum Clearances").
page 8
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SECTION 2
SPECIFICATIONS
2. Specifications
2.1. Physical Dimensions
64mm
390mm
28mm
205mm
295mm
FIGURE 1. D10 SMART / D10 TURBO SMART / D20 SMART PHYSICAL DIMENSIONS
2.2. Technical Specifications
D10 SMART
Input voltage
D10 Turbo SMART
Current consumption (mains)
250mA
Battery charger current
output
1.8A@ 27.4V +/-1%
Maximum number of
operations per day
Duty cycle - Mains present2,3
7503,6
45%
25%
45%
Battery-driven
(Standard Capacity - 2x 12V 7.2Ah)
Motor power supply
Current consumption
(motor at rated load)
D20 SMART
90V - 240V AC +/-10% @ 50Hz1
8A
10A
9A
Input / Output sink currents (Max. accessory current draw)
I/O 1-4
100mA (12/24V)
I/O 5 and 6
3A (12/24V) 10sec Pulse
Motor push force - starting
40kgf
24kgf
Motor push force - rated
30kgf
18kgf
39kgf
1000kg
250kg
2000kg
Gate mass - maximum
Gate length - maximum
Gate speed (varies with load)
52kgf
50m
50m
25m
Up to 26m/min4
Up to 45m/min8
Up to 18m/min4
Manual Override
Lockable with key release
TABLE 1
page 9
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SECTION 2
SPECIFICATIONS
2.2. Technical Specifications Continued
D10 SMART
D10 Turbo SMART
D20 SMART
Operating Mode
Power
saving
15m/
min
15kgf
Operations in standby
(7.2Ah Batteries)
Normal
26m/
min
15kgf
Power
saving
15m/
min
9kgf
Normal
45m/
min
9kgf
Power
saving
15m/
min
20kgf
Normal
18m/
min
20kgf
Half day3,5,6
118
63
189
130
101
55
Full day3,5,6
93
50
150
104
80
45
Collision Sensing
Electronic
Operating temperature
range
-15°C to +50°C
Onboard receiver type
Code-hopping multichannel receiver with
selective add and delete
Receiver code storage
capacity
1500 Remotes7
Receiver frequency
433.92MHz
Degree of protection
IP54
Mass of unit packed (with
standard kit, but excl. rack and
battery)
13kg
13.5kg
Packaging dimensions (with
standard kit, but excl. rack and
battery)
13kg
350mm wide
x 282mm deep
x 470mm high
Fuse Protection
Type
Main Control Card
Rating
Serviceable
25A
Aux. Supply
Resetable Fuse
24V 3A (10sec Pulse)
Charger (Mains Supply)
Non-serviceable
3A slow-blow
TABLE 1 CONTINUED
1.
2.
3.
4.
5.
6.
7.
8.
Can operate off a solar supply; consult your local dealer for assistance
Based on 25°C ambient temperature and unit not in direct sunlight
Based on a motor push force of less than 50% of rated (Starting and Running forces)
Gate opening and closing speeds can be configured to run slower depending on the requirements of individual installations
Can increase battery capacity for longer standby times
Based on 4m gate, excluding all accessories
Multiple buttons per remote can be used
Refer to the table below for D10 Turbo SMART’s recommended gate speed for specified gates masses
RECOMMENDED SPEEDS AND GATE MASSES FOR THE D10 TURBO SMART1
Max Speed (m/min)
Gate Mass (Kg)
Max Speed (m/min)
Gate Mass (Kg)
45
250
29
6002
41
300
27
7002
36
400
25
8002
32
500
24
9002
23
10002
TABLE 2
1. If a D10 Turbo SMART is used on a gate over 250Kg, the speed must be reduced according to the table above
to ensure that the gate can be safely stopped in an emergency.
2. Cenurion Systrems (Pty) Ltd recommends the use of a D10 SMART for gates weighing over 500KG.
page 10
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SECTION 3
PRODUCT IDENTIFICATION
3. Product Identification
1
22
21
20
2
3
3
19
18
4
5
17
6
16
15
7
8
9
10
11
12
13
14
FIGURE 2. PRODUCT IDENTIFICATION
1.
D10 SMART/ D10 Turbo SMART /
D20 SMART Cover
12. Release Handle
2.
DX Control Card
3.
7.2Ah 12V Battery1
14. Gearbox Trim
4.
M10 Nut
5.
Spring Washer
6.
Gearbox Mounting Washer
7.
Cable Shield
8.
Hex Height Adjustment Bolt (x4)
9.
Die-cast Aluminium Gearbox
13. Camlock
15. Cable Trunking
16. Earth Harness
17. Switch-mode Charger 27.4V 1.8A
18. Battery Harness
19. Power Supply Harness
20. Top Battery Stabiliser
21. Accessory Retaining Door
10. Foundation Plate
22. Accessory Tray
11. Override Cam
1. Batteries are not supplied with the D10 SMART / D10 Turbo SMART / D20 SMART.
page 11
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SECTION 4
REQUIRED TOOLS AND EQUIPMENT
4. Required Tools and Equipment
Hammer
Screwdrivers
6mm Phillips
3.5mm Flat
Ratchet and
Socket set
(12mm and 17mm)
with extensions
Electric Drill
Crimping tool
and Pin lugs
Smartphone
with app
installed
Connector
block
G-clamps
(x2)
Angle grinder
Pin punch
6mm
Measuring
tape
Masonry drill bits
Hacksaw
Safety equipment
(goggles, gloves, etc.)
Pliers
Welding machine
(including consumables)
and safety equipment
Marking
pen/chalk
Soldering
iron
Spirit level
Extension cord
FIGURE 3. REQUIRED TOOLS AND EQUIPMENT
page 12
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SECTION 5
NEW SITE INSTALLATION PREPARATION
5. New Site Installation Preparation
5.1. General Considerations for the Installation
Always recommend the fitment of additional safety equipment such as safety edges
and safety beams, for additional protection against entrapment or other mechanical
risks.
Check that no pipes or electrical cables are in the way of the intended installation.
Check that enough space is available for the gate operator, specifically for the
release handle, and removal of the Gearbox Trim (See Section 7.1.2. - "Minimum
Clearances").
Check for loose, sandy soil if installing a foundation, as the soil condition may require
a larger foundation.
Never fit the operator on the outside of the gate, where the public has access to it.
Install the gate operator only if:
•
It will not pose a hazard to the public
•
There is sufficient clearance to a roadway and/or public thoroughfares
•
The installation meets all municipal and/or local authority requirements once completed
•
The gate mass and application are within the operator specifications
•
The gate is in good working order, meaning:
•
•
that it opens and closes freely;
•
does not move on its own if left in any position;
•
it can be installed to have sufficient clearance between moving parts when
opening and closing to reduce the risk of personal injury and entrapment;
Pushbuttons or key-switches, when required, must be positioned so that the gate is in
line-of-sight of the user
page 13
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SECTION 5
NEW SITE INSTALLATION PREPARATION
5.2. Endstops
Fit opening and closing endstops capable of stopping the gate at rated speed. Refer to
the specifications at the beginning of this manual for the operating speed.
Make H1>H2 to ensure gate will not jump over the endstop.
Opening and closing endstops are mandatory and must be fitted to
prevent death or accidental injury as the operator uses and confirms
these limits during operation.
Endstop
Endstop
H1
H2
Ø16mm
FIGURE 4. FITTING ENDSTOPS
5.3. Guide-rollers and Anti-lift Brackets
Guide-rollers must be installed to ensure that the gate is held vertical. For improved
safety, fit additional support posts to prevent the gate from falling over should the
guide-rollers fail.
To prevent unauthorised access, fit anti-lift brackets as shown.
The gap between the anti-lift bracket and the gate must be less than 5mm.
Ensure that the gate cannot be lifted off the motor pinion with the anti-lift
bracket fitted.
Guide-rollers and
Anti-Lift Bracket
Side view of gate and different
Guide-roller options
GAP <5mm
GAP <5mm
GAP <5mm
GAP <5mm
Additional
support post
FIGURE 5. FITTING GUIDE-ROLLERS
page 14
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SECTION 5
NEW SITE INSTALLATION PREPARATION
5.4. Starting and Running Forces
Test the starting force of the gate as per Figure 6. Use a pull scale in both directions to
determine the maximum amount of pull force required to set the gate in motion.
Determine the running force of the gate by continuing to pull on the scale with just
sufficient force to keep it running.
Read and note the maximum value in kgf (kilogram-force) shown on the scale.
Where possible, determine the gate mass.
Our warranty will be void if the pull force and / or gate mass exceeds the below operator
specifications:
D10 SMART
•
Starting force - 40kgf
•
Running (rated) force - 30kgf
•
Maximum gate mass - 1000kg
D10 Turbo SMART
•
Starting force - 24kgf
•
Running (rated) force - 18kgf
•
Maximum gate mass - 250kg
D20 SMART
•
Starting force - 52kgf
•
Running (rated) force - 39kgf
•
Maximum gate mass - 2000kg
Pull Scale
FIGURE 6. STARTING AND RUNNING FORCES
page 15
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SECTION 5
NEW SITE INSTALLATION PREPARATION
5.5. Cabling Requirements
9
9
6
8
3
7
5
1
2
4
10
FIGURE 7. CABLING REQUIREMENTS
Legend
1.
MAINS SUPPLY CABLE: 90V - 240V AC mains cable via double-pole mains
isolator-switch (3 core L.N.E. 1.5mm2 SWA)1,2
2.
Optional intercom cable from motor to dwelling
(n1 + 6 core3 0.22mm2 multi-strand shielded cable)
3.
Optional intercom cable from motor to entry panel
(n2 0.22mm2 multi-strand shielded cable)
4.
Optional but recommended infrared safety beams
(3 core 0.22mm2 multi-stranded)4
5.
Optional access control device (3 core 0.22mm2 multi-stranded)
6.
Optional pedestrian key-switch (2 core 0.22mm2 multi-stranded) OR
7.
Optional keypad (3 core 0.22mm2 multi-stranded)4
8.
Optional external radio receiver (3 core 0.22mm2 multi-stranded)5
9.
Optional pillar lights (3 core LNE SWA, size according to power requirements)6
10. Optional ground loop for free-exit
(1 core 0.5mm2 multi-stranded – silicone coated)7
n1
n2
1.
2.
3.
4.
5.
6.
7.
means the number of cores required by an intercom
means the number of cores required by an 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 against lightning – earth one end of the screening).
Allows for all features such as pedestrian opening, status LED, etc., to be operated from the intercom handset inside the dwelling.
Number of cores and type of cable could vary depending on brand of access control system being used.
Wireless accessories are available. Please refer to www.censys.com for further information.
For optimum range, an external receiver can be mounted on the wall.
Requires an external relay
Consult manufacturer of loop detector for specific details.
page 16
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SECTION 6
LUBRICATION
6. Lubrication
The internal gearset of the D10 SMART / D10 Turbo SMART / D20 SMART is
lubricated by means of an oil bath.
The D10 SMART / D10 Turbo SMART / D20 SMART is supplied with oil in
its gearbox and does not require routine oil changes.
page 17
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SECTION 7
OPERATOR INSTALLATION
7. OPERATOR INSTALLATION
7.1. New Site Installations
When installing the D10 SMART / D10 Turbo SMART / D20 SMART, it is
important to take note of the information found in Sections 7.1.1. and 7.1.2.
when determining the position of the Foundation Plate, and the height of the
D10 SMART / D10 Turbo SMART / D20 SMART in relation to the gate that is
to be automated.
7.1.1. Locating an Initial Reference Point
Firstly, it is necessary to establish a reference point. To do this, manually open and close
the gate so that it moves past a stationary point (i.e. a vertical spike), and determine
which part of the gate (including its wheels) protrudes the furthest towards where the
D10 SMART / D10 Turbo SMART / D20 SMART will be installed. Refer to the
examples shown below.
Check for wheels, palisade, uprights, etc. that could potentially collide
with the pinion.
Palisade
Gate Rail
Gate
Palisade
Gate Rail
Warped Gate
GATE MOVEMENT
GATE MOVEMENT
Foundation
for D10 SMART /
D10 Turbo SMART
/ D20 SMART
Foundation
for D10 SMART /
D10 Turbo SMART
/ D20 SMART
Edge that
protrudes
protrudes
out
thethe
furthest
most
(Reference Point)
Palisade
Gate
Gate Rail
Gate
Edge that
protrudes
the furthest
(Reference Point)
Palisade
Gate Rail
Gate
GATE MOVEMENT
Foundation
for D10 SMART /
D10 Turbo SMART
/ D20 SMART
Possible
Collision
GATE MOVEMENT
Palisade
Edge that
protrudes
protrudes
out
thethe
furthest
most
(Reference Point)
Foundation
for D10 SMART /
D10 Turbo SMART
/ D20 SMART
Possible
Collision
Gate Wheel
Edge that
protrudes
protrudes
out
thethe
furthest
most
(Reference Point)
FIGURE 8. FINDING A REFERENCE POINT
Once the point which protrudes the furthest has been found, this will be the
reference point to be used when finding the optimum position for the
D10 SMART / D10 Turbo SMART / D20 SMART.
page 18
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SECTION 7
OPERATOR INSTALLATION
7.1.2. Minimum Clearances
Below are site plan examples illustrating the minimum clearances required when
installing the D10 SMART, D10 Turbo SMART or D20 SMART.
Gate Rack
Pillar
Pillar
Foundation
20mm (Minimum)
40mm and above(Ideal)
20mm (Minimum)
40mm and above(Ideal)
D10 SMART / D10 Turbo SMART
/ D20 SMART
Theft-deterrent Cage
FIGURE 9. MINIMUM CLEARANCES - SIDES
Gate Rack
Foundation
Trench
Trench
Most
extreme
path of
the Override
Lever
175mm
120mm
Gearbox
Trim
Trench
FIGURE 10. MINIMUM CLEARANCES - FRONT
page 19
www.centsys.com
SECTION 7
7.1.3.
OPERATOR INSTALLATION
Locating the Operator's Position
To ensure that the operator does not protrude into the driveway, install the base plate at
least flush with the driveway entrance.
It is typical to mount the rack above the pinion as shown in Figures 11, 13 and 15.
However, Figures 12, 14 and 16 shows the rack mounted underneath.
If there is space to mount the rack underneath without fouling the ground as the
gate moves, the following are the pros and cons:
Pros
•
The rack is more hidden from view
•
It provides a very effective anti-lift bracket
•
It ensures that, since the gate beds in, the rack does not drop onto the
pinion, loading the operator unnecessarily
Cons
•
Rack teeth face up vertically, potentially collecting dirt
•
Could require the use of a custom bracket
The measurements given below are based on the rack supplied by
Centurion Systems (Pty) Ltd and are to be used as guidelines only.
25mm
(Typical Steel
Rack Width)
Minimum space from edge
of Foundation Plate to
reference point of edge that
protrudes the furthest.
(Section 7.1.1.)
176mm1
121mm1,2
5mm
50mm
91mm
25mm (Recommended to allow
for adjustment)
D10 SMART - Steel Rack
Flat bar welded
to Foundation Plate
and rail
Concrete Foundation
Foundation Plate
FIGURE 11. STEEL RACK ABOVE PINION
1. Includes 3mm clearance required between rack and pinion
2. Distance between bottom of the Foundation Plate and bottom edge of the Rack Tooth
The principles of installation on a Steel Rack is to position it in the middle of the
output pinion with the operator fully forward on the slots.
page 20
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OPERATOR INSTALLATION
25mm
(Typical Steel
Rack Width)
Minimum space from edge
of Foundation Plate to reference
point of edge that protrudes
the furthest.
(Section 7.1.1.)
51mm1,2
50mm
5mm
25mm (Recommended to allow
for adjustment)
SECTION 7
Foundation Plate
Raised
Concrete
Foundation
FIGURE 12. STEEL RACK BELOW PINION
1. Includes 3mm clearance required between rack and pinion
2. Distance between bottom of the Foundation Plate and top edge of the Rack Tooth
The principles of installation on a Steel Rack is to position it in the middle of the
output pinion with the operator fully forward on the slots.
The Pinion Guard needs to be rotated 180 degrees if the rack below the pinion
is desired for ONLY the D10 SMART and D20 SMART, and not the D10 Turbo
SMART.
page 21
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SECTION 7
OPERATOR INSTALLATION
D10 Turbo SMART - Steel Rack
25mm (Recommended to allow
for adjustment)
25mm
(Typical Steel
Rack Width)
Minimum space from edge
of Foundation Plate to
reference point of edge that
protrudes the furthest.
(Section 7.1.1.)
182mm1
91mm
127mm1,2
5mm
50mm
Flat bar welded
to Foundation Plate
and rail
Concrete Foundation
Foundation Plate
FIGURE 13. STEEL RACK ABOVE PINION - D10 TURBO SMART
1. Includes 3mm clearance required between rack and pinion
2. Distance between bottom of the Foundation Plate and bottom edge of the Rack Tooth
25mm
(Typical Steel
Rack Width)
45mm1,2
Minimum space from edge
of Foundation Plate to
reference point of edge that
protrudes the furthest.
(Section 7.1.1.)
5mm
25mm (Recommended to allow
for adjustment)
The principles of installation on a Steel Rack is to position it in the middle of the
output pinion with the operator fully forward on the slots.
50mm
Foundation Plate
Raised
Concrete
Foundation
FIGURE 14. STEEL RACK BELOW PINION - D10 TURBO SMART
1. Includes 3mm clearance required between rack and pinion
2. Distance between bottom of the Foundation Plate and top edge of the Rack Tooth
The principles of installation on a Steel Rack is to position it in the middle of the
output pinion with the operator fully forward on the slots.
page 22
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SECTION 7
OPERATOR INSTALLATION
D20 SMART - Steel Rack
25mm (Recommended to allow
for adjustment)
25mm
(Typical Steel
Rack Width)
Minimum space from edge
of Foundation Plate to
reference point of edge that
protrudes the furthest.
(Section 7.1.1.)
168mm1
91mm
113mm1,2
5mm
50mm
Flat bar welded
to Foundation Plate
and rail
Concrete Foundation
Foundation Plate
FIGURE 15. STEEL RACK ABOVE PINION - D20 SMART
1. Includes 3mm clearance required between rack and pinion
2. Distance between bottom of the Foundation Plate and bottom edge of the Rack Tooth
25mm
(Typical Steel
Rack Width)
59mm1,2
Minimum space from edge
of Foundation Plate to
reference point of edge that
protrudes the furthest.
(Section 7.1.1.)
5mm
25mm (Recommended to allow
for adjustment)
The principles of installation on a Steel Rack is to position it in the middle of the
output pinion with the operator fully forward on the slots.
50mm
Foundation Plate
Raised
Concrete
Foundation
FIGURE 16. STEEL RACK BELOW PINION - D20 SMART
1. Includes 3mm clearance required between rack and pinion
2. Distance between bottom of the Foundation Plate and top edge of the Rack Tooth
The principles of installation on a Steel Rack is to position it in the middle of the
output pinion with the operator fully forward on the slots.
page 23
www.centsys.com
SECTION 7
OPERATOR INSTALLATION
7.1.4. Foundation Plate Installation
The Foundation Plate can either be set into a new concrete foundation, as in
Section 7.1.4.1, or bolted down onto an existing concrete plinth as in Section
7.1.4.2.
Cutout for Conduit
(New and Existing
Installations)
Bolt-down point for
existing Concrete Plinth
Bolt-down point for
existing Concrete Plinth
Towards Gate
Mounting Bolt
Mounting Bolt
Bolt-down point for
existing Concrete Plinth
Bolt-down point for
existing Concrete Plinth
Tab
Tab
FIGURE 17. FOUNDATION PLATE ASSEMBLY - TOP VIEW
7.1.4.1. New Concrete Foundation
View once tabs
have been bent
down correctly
Check that the M10 halfnuts are tightened to 20Nm
on the mounting bolts.
Using a pair of pliers, gently bend
the two tabs of the Foundation Plate
down to a 90° angle as shown in
Figure 16.
Be careful not to deform
the Foundation Plate
while bending the tabs.
Bottom face of the
Foundation Plate
Lay the cabling conduit so
that it routes the cables to
the back of the Foundation
Plate. Ensure that 30mm
of conduit protrudes above
the concrete.
Using medium-strength concrete
(25MPa), cast the plinth according to
the dimensions as shown in Figure 19.
300mm
FIGURE 18
m
0m
40
0m
m
30
Cabling conduit exiting at the
back of the Foundation Plate
FIGURE 19
page 24
www.centsys.com
SECTION 7
OPERATOR INSTALLATION
When using a concrete
foundation, it is
recommended that the
Foundation Plate is welded
to the rail/track of the gate
using a short length of flat
bar, as shown in Figure 20.
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
operator left in Manual
Mode until the concrete
has set. Do not operate the
motor until concrete has
completely set.
7.1.4.2. Existing Concrete Plinth
If bolting onto an existing concrete
plinth, place the Foundation Plate
down in the correct position and use
the plate as a template for marking
the Expansion Stud holes.
Rail
Foundation Plate
Flat bar welded to
Foundation Plate
and rail
FIGURE 20
Nut
Mounting
Bolt
Washer
Check that the M10 halfnuts are tightened to 20Nm
on the mounting bolts.
Ensure that the Expansion
Studs do not protrude more
than 23mm above the
Foundation Plate.
Expansion Stud
Rerouting of existing cables
may be necessary.
FIGURE 21
7.2. Retro-fit Installations (Existing Sites)
The D10 SMART / D10 Turbo SMART has been designed to retro-fit into existing D10
and D10 Turbo installations.
If the existing Foundation Plate is in a good condition, it is not necessary to replace
it with a new D10 SMART / D10 Turbo SMART Foundation Plate. However, if the
existing Foundation Plate is corroded or needs to be replaced for whatever reason,
the D10 SMART / D10 Turbo SMART Foundation Plate can accommodate the existing
footprint without the need to re-route cable conduits.
The D20 SMART is designed to fit existing foundation plates for D10 and A10
installations. However, there are potential sites where an A10 was mounted high on a
foundation plate, and the D20 SMART will not be able to reach the rack.
In these cases, the rack will need to be lowered.
page 25
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SECTION 7
OPERATOR INSTALLATION
7.3. Conduit and Cable Length
(Mains)450mm
Make sure that the conduits protrude
above the concrete foundation.
The mains cables should protrude
450mm above the concrete
foundation, and all signal cables
(i.e. beams, etc.) 600mm above the
concrete foundation, as shown in
Figure 22.
(Signal Cables) 600mm
Route the cables as determined in
Section 5.5 - "Cabling Requirements".
30mm
FIGURE 22
7.4. Preparing the Operator for Installation
FIGURE 23
Open the Camlock Cover,
and insert the Operator Key into the
Camlock. Unlock it by turning the
key anti-clockwise.
There is no need to open
the Release Handle to
remove the cover of the
D10 SMART / D10 Turbo
SMART / D20 SMART.
Camlock Cover
Operator Key
Camlock
FIGURE 23
Cover
Remove the cover of the D10
SMART / D10 Turbo SMART /
D20 SMART to expose the internal
components, and place it to one side
in a safe location.
Control Card
Control Card Platform
Charger
Gearbox
FIGURE 24
page 26
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SECTION 7
OPERATOR INSTALLATION
7.4.1. Removing the Charger
Disconnect the Charger from
the D10 SMART / D10 Turbo
SMART / D20 SMART Control Card
at either Point "A" or Point "B".
If the disconnection
is made at Point "A",
note that there are two
connector blocks that need
to be disconnected from
the Control Card.
Control
Card
Harness
A
B
Charger
C
Disconnect the Earth Harness from
the Charger at Point "C", and store it
in a safe place.
FIGURE 25
Power Supply
Harness
Remove the Charger from the lower
battery tray by gently pushing the
Charger slightly down whilst pulling
it towards the front of the
D10 SMART / D10 Turbo SMART /
D20 SMART. It should slide forward
and off with ease.
Battery
Harness
Charger
FIGURE 26
page 27
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SECTION 7
OPERATOR INSTALLATION
7.4.2. Removing the Gearbox Trim and Battery Tray Assembly
Locked
Locked
Locked
Unlocked
Unlocked
Unlocked
A
FIGURE 27
To remove the Gearbox Trim with the battery tray, firstly ensure that the Camlock is in
the "unlocked" position (Figure 27 marked as "A").
Open the Manual Override Lever so that it is in the 90° position. Remove the Camlock
Key, and keep it in a safe place. Hold the gearbox trim on both sides firmly and pull the
entire assembly forward with a slight tug towards the front of the D10 SMART / D10
Turbo SMART / D20 SMART. It will unclip from the rear of the gearbox. Manoeuver it
over the Manual Override Lever to remove it completely off the gearbox.
Electric Motor
Lower Battery
Tray
Cable Shield
Gearbox
Manual Override
Lever
Gearbox Trim
FIGURE 28
page 28
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SECTION 7
OPERATOR INSTALLATION
7.4.3. Removing the Control Card
D10 SMART
Control Card
Disconnect the Motor Wires at
Point "D" and the Override Sensor
Harness at Point "E" from the Control
Card as Shown in Figure 29.
Motor
Wires
D
E
Override Sensor
Harness
FIGURE 29
Hinge the Control
Card forward
Push the right tab
backwards
Remove the Control Card by pushing
the right tab behind the Control Card
backwards.
This will allow the Control Card to
hinge forward.
FIGURE 30
Lift the Control Card upwards and
away form the D10 SMART / D10
Turbo SMART / D20 SMART,
which will unhinge it from the hinge
tabs found on the sides of the
Control Card.
Take care not to snag the
remaining harnesses in the
harness retainers when
removing the Control Card
from the platform.
D10 SMART
Control Card
Harnesses
Harness
Retainer
Store the Control Card in a safe
place.
FIGURE 31
The D10 SMART / D10 Turbo
SMART / D20 SMART is now ready
to be mounted onto the Foundation
Plate.
page 29
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SECTION 7
OPERATOR INSTALLATION
7.5. Mounting the Gearbox
Removing the Cable Shield
Cable Shield
The Cable Shield needs to be
removed before mounting the D10
SMART / D10 Turbo SMART /
D20 SMART onto its Foundation
Plate. This is done by lifting the
Cable Shield up and away from the
gearbox.
Gearbox
FIGURE 32
Once the Cable Shield has been removed, place the D10 SMART / D10 Turbo SMART/
D20 SMART into position over the two Mounting Bolts, aligning them with the two slots
at the bottom of the gearbox and rest the D10 SMART / D10 Turbo SMART / D20
SMART onto the Foundation Plate.
Slot
Slot
Gearbox
Mounting
Bolt
Foundation
Plate
Mounting
Bolt
TOP VIEW
Mounting
Bolt
FIGURE 33
Once the Gearbox is resting on top
of the Foundation Plate, slide the
D10 SMART / D10 Turbo SMART
/ D20 SMART as far as possible
towards the gate to allow for later
adjustment.
FIGURE 34
page 30
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SECTION 7
OPERATOR INSTALLATION
7.6. Routing the Cables
A
Route cables as determined in
Section 5.5 - "Cabling Requirements".
POINT A is the entry point for cables
with the conduit installed at the back
of the unit as shown in Figure 35.
FIGURE 35
Section View A-A
A
A
A
FIGURE 36. CABLE ROUTING FOR NEW INSTALLATIONS
Replacing the Cable Shield onto the Gearbox
The Cable Shield has punch-outs on
it which cater for both Mains Cables
and Communication cables. Punch
out the holes which are needed and
place the Cable Shield back into
position onto the gearbox whilst
guiding the cables through the holes.
Mains
Punch-out
Communication cable
Punch-outs
Gearbox
Profile
Gearbox
Profile
Groove
There is a groove on either side
of the Cable Shield to guide it into
position.
Cable
Shield
Press firmly down, and you will hear
a "click" once the Cable Shield has
located correctly.
Gearbox
FIGURE 37
page 31
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SECTION 7
OPERATOR INSTALLATION
7.7. Manual Override
Before mounting the rack to the gate, ensure that the D10 SMART /
D10 Turbo SMART / D20 SMART is in Manual Override. Follow the
instructions below.
Release
Handle
To disengage (Manual Override) the
motor, ensure that the Camlock is
in the "unlocked" position, and pull
the Release Handle to a 90° position.
The Motor will then be placed in a
temporary state of disengagement.
Gearbox
Camlock
FIGURE 38
Manual Override Latching
In the event of a power failure,
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.
Release Handle
Override Cam
With the release handle in the open
position, slide the Override Cam
located on the inside of the handle
towards the gearbox, and a "click"
can be heard once it has located
correctly. Return the handle to the
closed, or locked, position. This
allows continued manual operation
of the gate while ensuring that the
cover remains securely locked in
place. See Figure 39.
To re-engage the D10 SMART /
D10 Turbo SMART / D20 SMART
(i.e. take the operator out of
latched Manual Override), push the
Release Handle Override Cam to the
right and then slide it towards the
Camlock. See Figure 40.
Release Handle
FIGURE 39
Release Handle
Release
Handle
Override
Cam
Camlock
FIGURE 40
page 32
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SECTION 7
OPERATOR INSTALLATION
7.8. Height Adjustment
The D10 SMART / D10 Turbo SMART / D20 SMART's unique Height Adjustment
System adjusts from the top of the gearbox. This adds further security to the system, as
it is not possible to access the Height Adjustment Bolts from the outside of the gearbox.
B
Height
Adjustment
Bolt
B
Foundation Plate
Section View B-B
FIGURE 41
Using a ratchet and a 12mm socket, turn the Height Adjustment Bolt clockwise to lift the
Operator, or turn it anti-clockwise, to lower the Operator.
Using a spirit level, ensure that the Operator is level. If not, use the four Height
Adjustment Bolts to level the Operator.
Lubricating the Height Adjustment Bolts with Q20 or a similar general purpose
lubricant will make adjusting the bolts easier.
Spirit Level
Control Card
Platfrom
Gearbox
Height Adjustment
Bolt
Foundation
Plate
FIGURE 42
page 33
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SECTION 7
OPERATOR INSTALLATION
7.9. Mounting the Rack
The rack must be securely 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
rack teeth and the teeth of the pinion.
The D10 SMART is supplied with
the Pinion Spyder1, which greatly
enhances the accuracy and speed of
achieving the 2-3mm gap between
the Pinion and the gate's rack.
Pinion Spyder
tooth
Pinion
Spyder
Fit the Pinion Spyder onto the Pinion
of the D10 SMART by aligning its
teeth with the gaps between the
teeth of the D10 SMART's Pinion.
Ensure that the D10 SMART Gearbox
is in Manual Override. Refer back to
Section 7.7 - "Manual Override".
FIGURE 43
Start with the gate either fully-open
or fully-closed.
Gate Rack
Slide the D10 SMART back towards
the gate to where the Pinion will sit
just under where the rack will be
fixed to the gate.
Rest the rack directly onto the Pinion
Spyder while welding / bolting the
rack into position.
Level the other end of the rack and
fix to the side of the gate, as shown
in Figure 45.
D10 SMART
Pinion
1. The Pinion Spyder is only supplied with the D10 SMART, and not the D10 Turbo SMART or D20 SMART
Pinion
Spyder
FIGURE 44
Spirit Level
Level this end of the rack,
and fix it to the gate
Pinion
Spyder
Pinion
Foundation Plate
FIGURE 45. THE RACK AND OPERATOR FROM THE GATE'S PERSPECTIVE
Refer to the instructions on how to fix the Steel Rack to a gate in Section 7.9.1. "Fitting Steel Rack to the Gate".
page 34
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SECTION 7
OPERATOR INSTALLATION
Slide the gate halfway along the first section and level the unsecured end, ensuring that
the rack is resting on the Pinion Spyder, not pressing down. Continue this way to fix all
sections.
Before fully fixing each section of rack, slide the gate backwards and forwards
along the section, checking that the rack is only resting on the Pinion Spyder,
and not pressing down onto it.
Spirit Level
First
Secured End
Pinion Spyder
Level this end of the rack,
and fix it to the gate
Foundation
Plate
Pinion
FIGURE 46. THE RACK AND OPERATOR FROM THE GATE'S PERSPECTIVE
7.9.1. Fitting Steel Rack to the Gate
Gate
Steel
Rack
Fix the Steel Rack with the steel
angle brackets1. The brackets must
be spaced no more than 300mm
apart.
±300mm
Steel
Bracket
Steel
Rack
FIGURE 47
Off-cut
Welded
join
When joining different lengths of
Steel Rack, a simple way of ensuring
that the correct pitch spacing is
achieved, is to clamp a small off-cut
between the two pieces.
Do not weld the off-cut
to the gate or the join.
±300mm
Clamp
FIGURE 48
1. The Steel Angle Brackets are not supplied with the D10 SMART / D10 Turbo SMART / D20 SMART.
page 35
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SECTION 7
OPERATOR INSTALLATION
7.9.2. Finalising the Height Adjustment
Once the rack has been fixed to the entire length of the gate, use a screwdriver to
carefully remove the Pinion Spyder from the Pinion of the D10 SMART.
Gate
Slide the D10 SMART
away from the gate so that
the rack is centred above
the Pinion.
Screwdriver
Final adjustment to the
position of the gearbox
should be done at this
point.
Pinion Spyder
Pinion
FIGURE 49
7.9.3. Placing the Gearbox Mounting Washers, Spring Washers and Lock Nuts
Only add the Gearbox Mounting Washers, Spring Washers and Lock Nuts once
the Rack has been installed and the operator height is correct.
Place one Gearbox Mounting Washer, one Spring Washer and one Lock Nut onto each of
the Mounting Bolts. Tighten all of the Lock Nuts with a 17mm socket to secure the height
of the D10 SMART / D10 Turbo SMART / D20 SMART firmly in position.
Lock Nut
Spring
Washer
Gearbox
Mounting
Washer
Gearbox
Mounting Bolt
Earth Harness
Gearbox
FIGURE 50
page 36
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SECTION 7
OPERATOR INSTALLATION
7.10. Re-assembling the D10 SMART / D10 Turbo SMART /
D20 SMART
7.10.1. Placing the Gearbox Trim and Charger back into Position
Ensure that the Camlock is in the "locked" position and that the Manual Override
Lever is open to the 90° position.
Ensure that the Manual Override Lever is in the open position, and slide the Gearbox
Trim into position. Whilst doing this, route the Earth harnesses through. A click from both
sides will be heard if the tray is fitted correctly.
Locked
Ensure that the Cam Driven
Slide is in the correct
position before placing the
Lower Battery Tray back into
the Gearbox.
i.e. Push it to the left.
Cam Driven Slide
Unlocked
Refer to Section 7.4 "Preparing the Operator
for Installation" for further
information on locked and
unlocked positions
Cam Driven Slide
Earth Harness
Gearbox
Manual Override
Lever
Gearbox
Trim
FIGURE 51. GEARBOX TRIM PLACEMENT
page 37
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SECTION 7
OPERATOR INSTALLATION
Electric
Motor
Slots
Place the Charger back into position
by aligning the three studs at the
bottom of the Charger with the three
slots found on top of the Gearbox
Trim.
Gearbox
Trim
Charger
Place the studs of the Charger into
the three slots on the Gearbox Trim.
Firmly press the Charger down, and
push it toward the Electric Motor,
sliding it along the slots.
Gearbox
Trim
Slot
FIGURE 52. CHARGER PLACEMENT
7.10.2. Placing the Control Card back into Position
Control Card
Platform
Tilt the Control Card towards the
back of the Control Card Platform
and align the wider gap with the
clips shown in Figure 53.
Ridge
Clip
Wider gap
Ridge
Left Tab
Control
Card
FIGURE 53
Left Tab
Once aligned, hinge the Control Card
under the tab's lip, and firmly press
downward on both sides in front of
the Control Card.
This will engage the Control Card
into the hinges at the front of the
Control Card Platform.
A click from both sides will be heard
if this is done correctly.
Right Tab
Control Card
Control Card
Platform
FIGURE 54
page 38
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SECTION 7
OPERATOR INSTALLATION
7.10.3. Reconnecting the Harnesses to the Control Card and Charger
Reconnect the Motor Wires at
Position "A" and the Override
Harness at Point "B" on the Control
card.
The black motor wire
is connected on the
far Left of the Control
Card, and the blue on
the immediate right of
the black.
A B
A
B
FIGURE 55
Reconnect the Charger Harness
to the point from which it was
disconnected earlier, either at
Position "C" or at Position "D".
If the connection is made
at Point "C", note that
there are two connector
blocks that need to be
reconnected to the
Control Card.
C
Harness
D
Charger
Utilise the Cable Retainers
at the bottom of the
accessory storage to neaten
up the wiring, and the
overall installation.
Connect the Earth Harness into the
right-hand side of the Charger at
Point "E".
FIGURE 56
Charger
E
Earth
Harness
FIGURE 57
page 39
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SECTION 7
OPERATOR INSTALLATION
7.11. Installing the Origin Sensor and Marker
The Origin Sensor and Marker is an optional extra for the D10 SMART, but is
mandatory to use for the D10 Turbo SMART, and the D20 SMART as a safety
precaution.
7.11.1. Installing the Origin Sensor
Origin Sensor
Harness
Locate the Origin Sensor and its
Harness
Origin
Sensor
FIGURE 58
Lower
Battery
Tray
Place the Origin Sensor into its
dedicated slot found just above the
Pinion on the Lower Battery Tray.
Origin
Sensor
Note the orientation of the
Origin Sensor.
Origin Sensor
Locating Slot
FIGURE 59
Route the Harness around the
electric motor to the front of the
operator, and through the cable
retainers found in front of the
Control Card.
Connect the Harness to the white
"Origin" Terminal found on the
Control Card.
FIGURE 60
page 40
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SECTION 7
OPERATOR INSTALLATION
7.11.2. Mounting the Origin Marker
Fully close
the gate
Firstly, close the gate completely.
FIGURE 61
500mm
Mount the Origin Marker to the rack
a minimum of 500mm from the
origin sensor. Refer to Figure 62.
Origin
Marker
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 not affect
the width of the pedestrian
opening, it is preferable to
have the marker mounted
inside of the pedestrian
opening point.
Top View
500mm
GATE CLOSED
Origin
Marker
Gate Rack
Origin Sensor
FIGURE 62
Note the orientation of the
Origin Marker.
Gate
Manually slide the gate open until
the origin marker is in line with the
origin sensor.
Rack
Ensure the distance between the
face of the marker and front face of
the sensor is between 10 and 20mm.
Adjust distance by sliding the Origin
Marker along the slotted mounting
holes until the specified distance is
achieved.
10-20mm gap
between the
Origin Marker and the
Origin Sensor
FIGURE 63
page 41
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SECTION 7
OPERATOR INSTALLATION
7.11.3. Mounting the Origin Marker onto the Steel Rack
Bolt using fasteners
provided
For Steel Rack, mount the Origin
Marker onto the Rack using the
bracket provided.
Origin Marker
Bracket
Weld the bracket to the Rack.
Bolt the Origin Marker onto the
Bracket using the fasteners
provided.
Ensure that the Origin
Marker is within +/- 10mm
of the Origin Sensor in the
vertical plane.
Weld Mounting Bracket
provided to the Steel Rack
FIGURE 64
page 42
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SECTION 8
COMPLETING THE INSTALLATION
8. Completing the Installation
8.1. Fitting the Batteries
Push the left tab
backwards
Swing the upper
assembly forward
Gently push the left tab behind the
Control Card backwards. This will
allow the entire upper assembly to
hinge forward.
FIGURE 65
Place a Battery into the designated
area found on top of the Gearbox
Trim on the left. Route the Signal
Wires below the Left Battery, and
the Power Cables behind the motor
and under the Right Battery then
place the remaining Battery in its
designated area on the right.
Note the orientation of
the two Batteries. Ensure
that the Battery Terminals
always face the direction of
the Charger.
Battery
Battery
Gearbox
Trim
FIGURE 66
Battery
Battery
Gearbox
Trim
Earth
Harness
Swing the upper assembly back into
position over the batteries.
A click should be heard if this is done
correctly.
Failure to properly click
the control card and
upper assembly into
place will result in erratic
behaviour of the gate
motor.
FIGURE 67
page 43
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SECTION 8
COMPLETING THE INSTALLATION
Battery
Harness
Connect both batteries up with the
supplied harness, and ensure that it
is connected to the left side of the
Charger.
Route the accessory cables around
the back of the Charger and through
the cable retainers found at the
bottom of the accessory storage.
Please ensure that the
battery connections match
the selected battery
terminals RED to RED,
BLACK to BLACK.
Charger
FIGURE 68
8.2. Accessory Installation and Storage
There are dedicated trays below the D10 SMART / D10 Turbo SMART / D20 SMART
Control Card to conveniently install and store any accessories connected to the Operator.
Control
Card
Opening the two retaining doors,
reveals the storage space for
accessory products, such as the
G-ULTRA, or External Receivers.
Right
Door
Left
Door
FIGURE 69
Accessory
Retaining
Door
Wire the accessory device to the
Operator, place it into the space
provided, and close the door.
G-ULTRA
FIGURE 70
page 44
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SECTION 8
COMPLETING THE INSTALLATION
8.3. Wiring the Control Card on its Default Settings
The D10 SMART / D10 Turbo SMART / D20 SMART Control Card's Input / Output
terminals are defaulted with the following configuration;
Control Card
Terminal
Control Card
Terminal
Default Setting
Default Setting
I/O1
Trigger (TRG)
I/O4
Gate Status
I/O2
Pedestrian (PED)
I/O5
Free-exit (FRX)
I/O3
Infrared Beam Close (IRBC)
I/O6
Safe Common
TABLE 3
8.3.1. Closing Infrared Beam Wiring (i5 Infrared Beams)
Control Card
IRB Receiver
12V/24V 12V/24V +
COM
NC
COM
NC
NO
IRB Transmitter
12V/24V +
12V/24V -
Please contact Centurion
Systems (Pty) Ltd for directions
on wiring Infrared Beams in an
opening configuration.
FIGURE 71
page 45
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SECTION 8
COMPLETING THE INSTALLATION
8.3.2. Closing Infrared Beam Wiring (Photon Infrared Beams)
Control Card
IRB
Receiver
12V/24V +
12V/24V COM
NC
COM
NC
NO
Wireless IRB
Transmitter
Please contact Centurion
Systems (Pty) Ltd for directions
on wiring Infrared Beams in an
opening configuration.
FIGURE 72
page 46
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SECTION 8
COMPLETING THE INSTALLATION
8.3.3. External Radio Receiver and Loop Detector Wiring
Free-exit Loop
Control Card
12V/24V 12V/24V +
COM
NC
COM
NO
NO
Loop Detector
External Radio
Receiver
12V/24V 12V/24V +
COM
NC
COM
NO
NO
FIGURE 73
page 47
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SECTION 8
COMPLETING THE INSTALLATION
8.3.4. G-ULTRA to D10 SMART / D10 Turbo SMART / D20 SMART Wiring
G-ULTRA
GND IO1
RELAY 1
IO2
IO3
IO4
NO
COM
RELAY 2
NC
NO
COM
NC
+ VDC -
STATUS
FRX
PED
TRG
12V/24V +
COM
Control Card
FIGURE 74
8.4. Commissioning the System
1. Scan the QR Code in Figure 75.
Download on the
2. Select the App Store applicable
to the operating system being
used, either Apple App Store,
Android Google Play Store or the
Huawei App Gallery.
App Store
Minimum Requirements:
• BLE-enabled mobile phone
• iPhone 5s and above
• iOS10
3. Download and install the
application.
Alternatively, go directly to the
app store of the operating system
being used, and search for the
app "MyCentsys Pro". Download
and install the application onto the
smartphone.
Get it on
Minimum Requirements:
• BLE-enabled mobile phone
• Android 5.0. (Lollipop)
FIGURE 75
1. Once installed, open the
application.
2. From the list of operators, select the operator that is applicable to this installation.
3. Connect to the relevant operator.
4. Use the app by following the prompts to configure the D10 SMART / D10 Turbo
SMART / D20 SMART.
page 48
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SECTION 8
Once all the necessary accessories
and harnesses have been connected,
ensure that the Camlock is in the
"unlocked" position, and place the
D10 SMART / D10 Turbo SMART
/ D20 SMART cover onto the
gearbox.
COMPLETING THE INSTALLATION
D10 SMART
cover
Once the cover is secured in place,
lock the Camlock to lock the cover
in place.
D10 SMART
gearbox
FIGURE 76
8.5. Applying the Warning Decal
Apply the supplied warning decals to
the gate as indicated on the reverse
side of the decal.
FIGURE 77
page 49
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SECTION 9
GENERAL MAINTENANCE
9. General Maintenance
9.1. Gate Maintenance
Description
Frequency
Corrective Action
Daily
Clean around the gate and gate
operator. Consider installing gate
brooms on the bottom of the gate
Ensure that the
endstops are sturdy
and secure
Every 3 months
If the endstops are damaged or loose,
contact an installer to replace
Check that the rack is
securely mounted to
the gate over its full
length
Every 3 months
Contact installer
Contact an installer to
inspect and verify that
all safety equipment,
e.g. safety beams, is
functioning correctly
Every 6 months
N/A
Ensure that the gate
track is clear of debris
at all times
Ensure that the gate
moves smoothly when
in Manual Override.
Every 6 months
Check wheels and
guide-rollers
forMaintenance
signs
9.1.
SMART
of wear
Place the motor in Manual Override
and manually open and close the gate.
If the wheels and/or guide-rollers
are excessively worn, contact an
installer to replace
Check the track for
damage or corrosion
Every 6 months
If the track is damaged, contact an
installer to replace
If pedestrian gate /
emergency gate is fitted
within the main gate,
ensure that the lock
operates smoothly
Every 6 months
Dry lubricate if necessary (graphite)
TABLE 4
page 50
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SECTION 9
GENERAL MAINTENANCE
9.2. D10 SMART / D10 Turbo SMART / D20 SMART Maintenance
Before performing any maintenance, ensure that the D10 SMART /
D10 Turbo SMART / D20 SMART is isolated or is disconnected from
the mains supply!
Description
Frequency
Corrective Action
Clean and remove any nests that are
settling in and around the motor and
Control Card
Check for insect
infestations
Every 3 months
Check that the
mounting nuts are tight
on the foundation plate
bolts
Every 6 months
Torque setting 20Nm
Check that there is no
sand build-up inside the
unit
Every 6 months
Remove batteries and lower battery
tray and clear out the sand build-up
Check pinion and rack
engagement
Every 6 months
If the mesh is too loose or the rack is
riding on the pinion, contact an installer
to correct
Check the condition of
the pinion
Every 6 months
If the pinion is excessively worn,
contact an installer to replace
Check the condition of
the override camlock
Every 6 months
Dry lubricate if necessary (graphite)
If used, check the
condition of the theftdeterrent cage
Every 6 months
Ensure that the device is serving its
purpose
If used, check the
condition of the theftdeterrent cage lock and
that it operates
Every 6 months
Dry lubricate if necessary (graphite)
Insert a moth ball, which may
help to repel insects, at the
bottom of the gearbox
TABLE 5
page 51
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SECTION 10
INSTALLATION HANDOVER
10. 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 they know how to SAFELY operate
it. Make sure that the user fully understands the following safety requirements before
finally handing over the site.
The following needs to be understood by the user:
•
How to operate the Manual Release mechanism.
(Show them how by demonstration)
•
How the obstruction detection and all other safety features work.
(Show them how by demonstration)
•
All the features and benefits of the Operator, i.e. Beams, etc.
•
All the safety considerations associated with operating an automated gate. The user
should be able to pass this knowledge on to all other users of the automated system
and must be made aware of this responsibility.
•
Do not activate the Gate Operator unless you can see it and can determine that
its area of travel is clear of people, pets, or other obstructions
•
DO NOT CROSS THE PATH OF A MOVING GATE. Always keep people, pets and
objects away from a moving 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
•
Avoid close proximity with moving parts where fingers, hands or clothing could
be pinched and caught
•
Secure all easily-accessible gate operator controls in order to prevent
unauthorised use of the gate
•
Keep the automated gate system properly maintained, and ensure that all
working areas are free of debris and other objects that could affect the gate
operation and safety
•
On a monthly basis, check the obstruction detection system and
safety devices to ensure correct operation
•
All repair and service work to this product must be done by a
suitably qualified person
•
This product was designed and built strictly for the use documented herein. Any
other uses not included herein, could compromise the operating condition of
the product and/or be a source of danger!
Centurion Systems (Pty) Ltd does not accept any liability caused by improper use of
the product, or for use other than that for which the automated system was designed.
Ensure that the customer is in possession of the User Guide and that you have
completed the installation details in the back of the User Guide.
page 52
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SECTION 11
WARRANTY INFORMATION
11. Warranty Information
You can register your product(s) online at www.centsys.com, which will assist
you in keeping a record of your date of purchase or installation, serial numbers,
etc.
All of our products are manufactured with extreme care, thoroughly inspected and tested.
The goods supplied by us shall be subject to the provisions of sections 55 to 57 of
the Consumer Protection Act (68/2008) except where the provisions of the warranty
contained in our product documentation are more favourable to the purchaser.
Subject to the warranty contained in our product documentation, if applicable, our
products are warranted for a period of twenty-four months after delivery.
However, it is expressly noted that batteries carry a six month warranty due to the
nature of these products being such that they are subject to possible misuse. Please
note that warranties will be honoured on a carry-in basis; in other words, the product in
question must be taken in to one of our branches, or to the authorised reseller that the
product was purchased from, for assessment and, if necessary, repair. For equipment
not of our manufacture, the warranty as supplied by the original manufacturer will apply
if such warranty is more favourable to the purchaser than the relevant provisions of the
Consumer Protection Act (Act 68/2008 of South Africa), or any other applicable law
as so required in different countries in which the product was sold.
Such warranty is valid only once full payment has been received for such goods.
Australian customers:
Our goods come with guarantees that cannot be excluded under the Australian Consumer
Law. You are entitled to a replacement or refund for a major failure and compensation for
any other reasonably foreseeable loss or damage. You are also entitled to have the goods
repaired or replaced if the goods fail to be of acceptable quality and the failure does not
amount to a major failure
Any warranty may be voidable on any equipment which:
1. Has not been installed in accordance with the installation instructions provided.
2. Has been subject to misuse or which has been used for any purpose other than that
designed for by the manufacturers.
3. Has damage caused as a result of handling during transit, atmospheric conditions
(including lightning), corrosion of metal parts, insect infestation, power surges or
other forces outside of the control of the manufacturer.
4. Has been repaired by any workshop and / or person NOT previously authorised by the
manufacturer.
5. Has been repaired with components not previously tested, passed or authorised by
Centurion Systems (Pty) Ltd, South Africa or one of its subsidiary companies.
page 53
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Notes
page 54
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Notes
page 55
www.centsys.com
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Call Centurion Systems (Pty) Ltd . South Africa
Head Office: +27 11 699 2400
Call Technical Support: +27 11 699 2481
Monday to Friday: from 07h00 to 18h00 (GMT+2)
Saturday: from 08h00 to 16h30 (GMT+2)
www.centsys.com.au
Call: 1300 CENTSYS (1300 236 879)
After Hours International Technical Support Call Centre
+27 11 699 2481 (16:00 to 02:00 - Australian Eastern Time)
E&OE Centurion Systems (Pty) Ltd reserves the right to change any product without prior notice
All product and brand names in this document that are accompanied by the ® symbol are registered trademarks
in South Africa and/or other countries, in favour of Centurion Systems (Pty) Ltd, South Africa.
The CENTURION and CENTSYS logos, all product and brand names in this document that are accompanied by the TM symbol
are trademarks of Centurion Systems (Pty) Ltd, in South Africa and other territories; all rights are reserved.
We invite you to contact us for further details.
ISO 9001:2015
Doc number: 1271.D.01.0001_1
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