D10/D10 Turbo Industrial Sliding Gate Motor Pocket Mechanical Installation Guide

D10/D10 Turbo Industrial Sliding Gate Motor Pocket Mechanical Installation Guide
D10 and D10 Turbo
Pocket Mechanical
Installation Guide
TM
TM
INDUSTRIAL
SLIDING GATE
OPERATOR
1. Introduction
This guide is designed specifically for installers who are familiar with
the installation of standard sliding gate motors, but do not know the
specifics of the D10 and D10 Turbo.
Always ensure that all the safety instructions described in the
installation manual are adhered to during and after the installation
process is completed.
2. Important Safety Instructions
Please do not proceed with the installation until you have
read and fully understand the Safety Instructions
included in your product packaging
The Safety Instructions are also available on
www.CentSys.com, and may also be obtained by
contacting Centurion Systems on +27 860 236 887
or +27 11 699 2400
3. Icons used in this guide
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
4. General Description
The D10 is a heavy duty sliding gate operator designed to open and
close sliding gates. The D10 Turbo is perfectly suited for sites with
lighter gates requiring a high number of operations per day and very
fast opening and closing speeds, and can reach almost double the
speed of the standard D10. However, it is recommended that very
heavy gates are not operated at maximum speed, as the inertia
generated by heavier loads might prove detrimental to the gearbox at
such high speeds. A die-cast aluminium gearbox, coupled to a
powerful 24V DC motor and switch mode charger, make the D10 the
automatic choice for townhouse complexes and office parks. Gate
travel limits are managed by an opto-electronic system, comprising of
a gate-mounted origin magnet and an internal rotary encoder. This
system yields precise and repeatable control over gate position.
5. D10/D10 Turbo Identification
1
9
2
3
10
4
11
5
12
6
13
7
8
1.
D10/D10 Turbo controller
8.
Foundation plate
2.
Courtesy light fuse (3A F/B)
9.
Motor fuse (30A ATO)
3.
2 x 12V 7.2Ah batteries
10. D10/D10 Turbo charger
4.
Gate-mounted origin marker
11. Manual Release handle
5.
Origin marker bracket
12. Lock cover
6.
Origin sensor (clip under
battery)
13. Encoder sensor
(clip behind charger)
7.
Lower cover
6. Technical Specifications
It is a 24V DC battery-operated unit with the following limitations:
D10
D10 Turbo
Operator push force - starting
40kgf
20kgf
Operator push force - rated
30kgf
15kgf
Gate mass – maximum
1000kg
1000kg
Gate length – maximum
100m
50m
750
750
Maximum numbers of operations per day
Based on a push force of less than 50% of rated
With a brush replacement interval of two years
Depends on speed setting
D10 Turbo maximum operating speed for corresponding gate mass
Gate mass (kg)
Operator max. running speed (m/min)
240
50
300
42
400
36
500
32
600
29
700
27
800
25
900
24
1000
23
7. Preparation of site
General considerations for the installation
For comprehensive information, please refer to the full installation
manual available for download on www.centsys.com.au
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 will meet all municipal and/or local authority
requirements once completed
 The gate mass, length and application is within the operator
specifications
 The gate is in good working order, meaning:
 That it moves freely
 Does not move on its own if left in any position
 It can be installed to have sufficient clearance between
moving parts when opening and closing to reduce the risk of
personal injury and entrapment
scale
 Pushbuttons or keyswitches, whenPull
required,
can be positioned
so that the gate is in line of sight of the operator
Make sure the gate mass,
starting - and rated-pull-force
limitations are not exceeded.
Typical anti-lift
arrangements
Guide-rollers must ensure that
the gate is held vertically through
the entire length of the gate
travel. For improved safety fit
additional support posts to
prevent gate from falling over
if guide rollers fail.
GAP<5mm
GAP<5mm
Additional
support post
Guide-rollers
GAP<5mm
GAP<5mm
Ensure that the gate
cannot be lifted off the
motor pinion with the
anti-lift bracket fitted
Endstops
Endstop
Endstop
Ø16mm
Fit endstops capable of stopping the gate at rated speed.
Make H>h to ensure gate will not jump over endstop as shown
above
Since the D10 Turbo operates at exceptionally high speeds, it is
mandatory to install the following additional safety equipment in order
to ensure the safest possible installation:
 Opening safety beams, which will prevent the gate from moving
should anyone be in the path of the gate while opening
 Closing Safety Beams, which will prevent the gate from moving
should anyone be in the path of the gate while closing
 Passive Sensitive Edge to help absorb the kinetic energy of the
gate in the event of a collision and provide additional time for the
inherent electronic anti-crushing technology of the operator to
react. Must be installed on all shearing edges
Closing
Safety Beams
Passive
sensitive
edge
Opening
Safety Beams
Additionally, the IRBOC feature must be invoked on the
controller so that the gate will immediately reverse direction,
in the event of a collision, regardless of whether it is
commencing with the opening or closing cycle
8. Lubrication
Do not attempt to run the operator without first filling the
gearbox with lubricant
In order to prevent possible leakage during shipping, the unit is
shipped with no oil inside the gearbox. A bottle containing 80ml of a
special synthetic oil is included with the product, and this must be
introduced before operating the product.
Oil specifications
Oil filling
procedure
It is more convenient to
introduce oil before
bolting the unit down, as
shown in the illustration
below. The D10/
D10 Turbo does not
require routine oil
changes. However, in the
event of the unit losing oil
due to stripping down or
mechanical damage, the
correct replacement oil is
Castrol SAF XO 75W-90
synthetic final drive
lubricant
CENTURION product code:
OIL80ML0X0/H
Castrol SAF-XO 75w-90 Synthetic Final
Drive Lubricant
 Remove dipstick from gearbox
 Cut the tip off the nozzle which will allow for the oil to pass
through the nozzle; unscrew the oil bottle cap; remove the
seal from beneath the oil bottle cap; replace the oil bottle
cap onto the bottle and attach the extension tube to the
nozzle
 Fill the gearbox with the oil provided
9. Cabling Requirements
8
7
6
8
5
Legend
1.
90V-240V AC mains cable via double pole mains isolator switch
(3 core LNE 1.5mm2 SWA)
Optional wiring (all cable is multi-stranded):
2.
Intercom cable from motor to dwelling (n1 + 6 core 0 .5mm2)
3.
Intercom cable from motor to entry panel (n2 0.5mm2)
4.
Safe Close and
Recommended infrared Safety
Beams
Safe Open:
(3 core 0.5mm2)
6.
Ped:
Optional Pedestrian Keyswitch (a) or keypad
(b) (3 core 0.5mm2 )
7.
Trg:
Optional external radio receiver (3 core 0.5mm2)
8.
Light:
Optional Pillar Lights (3 core LNE SWA, size according
to power requirements)
n1 = number of cores required by intercom
n2 = number of cores required by intercom
Possibly increase cable thickness if pillar lights are installed
Type of cable must adhere to municipal bylaws but typically SWA
(steel wire armoured) cable is recommended. The armouring
provides excellent screening, which gives better protection 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
For optimum range, an external receiver can be mounted on the
wall
10. Manual Operation
Manual Release
operation
In the event of a power
failure, or product
malfunction, it may be
required to lock the cover
in place whilst 'latching'
the Manual Release (i.e.
Manual Release
permanently enabled).
This helps prevent theft of
the unit, or its
components, and provides
full protection from the
elements
1.
Manual Release handle in
closed position.
2.
Open lock cover and insert
key. Turn the key a quarterturn, counter-clockwise to
unlock.
3.
Pull the Manual Release
handle down to enable
Manual Release.
Manual Release
latching
Now that the Manual Release is
enabled, you may follow the
process below to lock the cover in
place.
4.
With the release handle
lowered, insert the split pin,
(supplied with the mounting
hardware kit), through the
hole in the gearbox as
indicated.
5.
Make sure that the split pin
goes all the way in as
shown.
6.
Raise handle and then turn
key a quarter-turn clockwise
to lock. Remove key and
close lock.
11. D10/D10 Turbo Operator Installation
Ensure that all the standard considerations for a quality
gate installation are adhered to as detailed in
CENTURION’s detailed installation manuals.
These must include:
 Correct access in and out of the premises
 Endstops are mandatory and must be capable of stopping the
gate at rated speed
 Guide-rollers and anti-lift brackets are correctly fitted
 The gate mass, starting- and rated-pull-force limitations are not
exceeded
 The D10/D10 Turbo is positioned correctly and does not
protrude into the driveway
Determine a suitable position
and vertical height for the
operator as shown in the
illustration
156
2.
92
To ensure operator does not
protrude into driveway, install
foundation plate at least flush
with the driveway entrance.
5
1.
(Recommended to
allow for adjustment)
Locate operator position
Foundation
43 - 53
plate
Flat bar welded to
foundation plate and rail
* Includes 3mm clearance required
between rack and pinion
Foundation plate installation
The foundation plate can either be set into a concrete foundation, or
bolted down onto an existing concrete plinth, refer to illustrations
below.
Option 1:
New concrete foundation
M10
gearbox
mounting
bolts
Cable conduits
Gate rail
200mm
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 the
illustration. 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.
250mm
400mm
 Ensure that the M10 gearbox mounting bolts are properly
tightened
 Cable conduits must be installed before pouring the concrete
Option 2:
M10
gearbox
mounting
bolts
Bolting foundation
plate ontoan existing
concrete plinth
200mm
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
rawl bolt holes.
Existing
concrete
plinth
250mm
400mm
Ensure that the M10 gearbox mounting bolts are properly
tightened
Route cables and secure foundation plate
1.
Route cables as determined
in Section 9: Cabling
requirements.
2.
The cable conduits or
SWA cable glands should
terminate onto the cable
termination flange provided
in the foundation plate, as
depicted in the illustration
3.
500mm
Cable
termination
flange
M10
mounting
bolts
Make sure that all cables
protrude at least 500mm
from the cable termination
flange.
If bolting the foundation
plate, the left-hand
concrete anchor may need
to be broken off in order to
clear incoming conduits
M8 captive nuts
Make sure that the M10
bolts, which secure the
gearbox, are in place
1.
Insert M8 captive nuts for the
jacking screws as shown.
2.
Screw the M8 grub screw
jacking screws into the
captive nuts.
Jacking
Screw
3.
Adjust jacking screws to give
4-6 mm chassis foundation
plate clearance.
A 4mm Allen key with
“ball end” is handy
4-6mm
Mount the steel rack
3mm
tooth gap
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 teeth of
the pinion and the rack,
along the entire travel of
the gate
±300mm
1.
Fix rack using the steel angle
brackets provided.
2.
Brackets must be spaced no
more than 300mm apart.
3.
When joining different
lengths of steel rack, a
simple way of ensuring
correct pitch spacing, is to
clamp a small off-cut
between the two pieces.
±300mm
Mounting the
origin marker
1.
Close the gate completely.
2.
Mount the origin marker to
the rack a minimum of
500mm from the origin
sensor.
Isometric view
Greater than 500mm
Bolt using
fasteners
provided
3.
For steel rack, mount the
origin marker onto the rack
using the bracket provided.
4.
Weld the bracket to the
rack.
5.
Bolt the origin marker onto
the bracket using the
fasteners provided.
Origin marker
bracket
Weld mounting
bracket provided to
steel rack
Steel rack
6.
Manually slide the gate
OPEN until the origin
marker is in line with the
origin sensor.
7.
Ensure distance between
face of marker and front
face of sensor is between
13 and 20mm.
Take care with the
orientation of the arrow on
the origin marker. This
arrow must face the
operator
Plan view
Greater than 500mm
Origin
marker
Origin
sensor
Gate in
closed
position
Plan view
8.
Origin
marker
Adjust distance by sliding
the origin marker along the
slotted mounting holes
until the specified distance
is achieved.
For best results keep gap
between marker and
sensor as small as
possible
Gate
Rack
13-20mm
Origin
sensor
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
Apply warning decal/signage
Apply the supplied Warning! decals/signage to the gate
12. Basic Maintenance
CENTURION operators are designed to be maintenance-free. However,
there are some basic checks that should be carried out regularly,
(every six months). These checks will increase the long term reliability
of the system and prevent erratic operation of your gate.
Isolate mains supply as well as disconnecting the
battery before cleaning or working on the equipment.
General
 Keep the track clear of stones, dirt and obstructions
 Ensure that all rollers run freely
 Put the operator into Manual Mode and check that the gate runs
freely on its rail and does not catch or foul against the walls or
pillars
 Ensure that the gate wheels and guide-rollers are rotating freely
and are not worn. In high-volume applications it will be necessary
to replace these components regularly
 Ensure that the rack is properly secured to the gate and that it
does not press down onto the operator pinion at any point along
its travel
 Keep shrubs and vegetation clear of the motor and rack
 Check that the key still operates the camlock - spray with
lubrication if necessary
 Keep the inside of the motor housing clear of insects and dust
Battery
CENTURION operators, which are fitted with maintenance-free leadacid batteries, should provide at least three years of normal service
life.
For sites utilising an external large capacity (+/-35Ah)
low-maintenance battery, ensure that the level of liquid (electrolyte
level) is correct.
In all instances check for corrosion of the battery terminals. Clean and
apply copper based grease as necessary.
Charger
The D10 and D10 Turbo operators have chargers separate to the
main controller. In the case of product malfunction, the charger fuse
should be checked, but only by a qualified electrician. Always isolate
the mains supply to the operator before attempting to remove and
check the fuse.
Check the ‘Mains Present’ icon on the main diagnostic screen or switch
to the battery charger diagnostic screen and check the charger voltage
– right-hand value. This should indicate, 27.6V for the D10 and D10
Turbo. Each charger has a red light (LED) to indicate mains supply.
Gearbox Oil Level
Check the oil level as described in section 8 of this document or refer
to the online manuals on our website, (www.CentSys.com).
Alternatively, please contact your CENTURION installer for assistance.
13. 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.
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. Safety Beams,
ChronoGuard, 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
 NO ONE MAY CROSS THE PATH OF A
MOVING GATE. Always keep people and objects away
from the gate and its area of travel
 NEVER LET CHILDREN OPERATE OR PLAY WITH THE
GATE CONTROLS, and do not allow children or pets near
the gate area
 Be careful with moving parts and avoid close proximity
to areas where fingers or hands could be pinched
 Secure all easily accessed gate operator controls in
order to 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 for 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
indicated in this documentation. Any other use, not
expressly indicated here, could compromise the good
condition/operation 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.
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.0047_18032014
www.CentSys.com
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