CAME GARD PX Brushless User manual

Automatic road barriers
GARD PX Brushless
GPX40MGC
INSTALLATION MANUAL
FA01556-EN
EN English

DEVICE MANUAL RELEASE
Releasing the device may be dangerous for the user, if the boom fastening has been damaged or if the boom is no longer intact, as the result of an
accident or installation error.
In these cases, the tensioned springs no longer guarantee that the boom is balanced. The boom may suddenly rotate when being released.
With the gearmotor released, the operator does not work.
1
2
2
1

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GENERAL PRECAUTIONS FOR INSTALLERS
Important safety instructions.
Please follow all of these instructions. Improper installation may cause serious bodily harm.
Before continuing, please also read the general precautions for users.
Only use this product for its intended purpose. Any other use is hazardous. • The manufacturer cannot be held liable for
any damage caused by improper, unreasonable or erroneous use. • This product is defined by the Machinery Directive
(2006/42/EC) as partly completed machinery. • Partly completed machinery means an assembly which is almost
machinery but which cannot in itself perform a specific application. • Partly completed machinery is only intended to be
incorporated into or assembled with other machinery or other partly completed machinery or equipment thereby forming
machinery to which the Machinery Directive (2006/42/EC) applies. • The final installation must comply with the Machinery
Directive (2006/42/EC) and the European reference standards in force. • The manufacturer declines any liability for using
non-original products, which would also void the warranty. • All operations indicated in this manual must be carried out
exclusively by skilled and qualified personnel and in full compliance with the regulations in force. • The device must be
installed, wired, connected and tested according to good professional practice, in compliance with the standards and
laws in force. • Make sure the mains power supply is disconnected during all installation procedures. • Check that the
temperature ranges given are suitable for the installation site. • Make sure that opening the automatic barrier does not
constitute a hazard. • Do not install on slopes i.e. any surfaces that are not perfectly level. • Do not install the operator on
surfaces that could yield and bend. If necessary, add suitable reinforcements to the anchoring points. • Make sure that
no direct jets of water can wet the product at the installation site (sprinklers, water cleaners, etc.). • Make sure you have
set up a suitable dual-pole cut-off device along the power supply that is compliant with the installation rules. It should
completely cut off the power supply according to category III surcharge conditions. • Demarcate the entire site properly
to prevent unauthorised personnel from entering, especially minors. • In case of manual handling, have one person for
every 20 kg that needs hoisting; for non-manual handling, use proper hoisting equipment in safe conditions. • When the
operator is being fixed in place, it may be unstable and overturn. Be careful and do not lean on it until it is fully fastened
in place. • Use suitable protection to prevent any mechanical hazards due to persons loitering within the operating range
of the operator. • The electrical cables must pass through special pipes, ducts and cable glands in order to guarantee
adequate protection against mechanical damage. • Make sure that the moving mechanical parts are suitably far away
from the wiring. • The electrical cables must not touch any parts that may overheat during use (such as the motor and
transformer). • All fixed controls must be clearly visible after installation, in a position that allows the guided part to be
directly visible, but far away from moving parts. In the case of a hold-to-run control, this must be installed at a minimum
height of 1.5 m from the ground and must not be accessible to the public. • If the passage is wider than 3 m, you must
use a fixed support for the boom. • If not already present, apply a permanent tag that describes how to use the manual
release mechanism close to it. • Make sure that the operator has been properly adjusted and that the safety and protection
devices and the manual release are working properly. • Before handing over to the final user, check that the system
complies with the harmonised standards and the essential requirements of the Machinery Directive (2006/42/EC). • Any
residual risks must be indicated clearly with proper signage affixed in visible areas, and explained to end users. • Put the
machine’s ID plate in a visible place when the installation is complete. • If the power supply cable is damaged, it must
be immediately replaced by the manufacturer or by an authorised technical assistance centre, or in any case, by qualified
staff, to prevent any risk. • Keep this manual inside the technical folder along with the manuals of all the other devices
used for your automation system. • Make sure to hand over to the end user all the operating manuals of the products that
make up the final machinery.

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Main points of danger for people
Risk of trapping hands.
No transiting.
DISMANTLING AND DISPOSAL
CAME S.p.A. employs an Environmental Management System at its premises. This system is certified and compliant with the UNI EN ISO 14001 standard to
ensure that the environment is respected and safeguarded. Please continue safeguarding the environment. At CAME we consider it one of the fundamentals of our
operating and market strategies. Simply follow these brief disposal guidelines:
DISPOSING OF THE PACKAGING
The packaging materials (cardboard, plastic, etc.) can be disposed of easily as solid urban waste, separated for recycling.
Before dismantling and disposing of the product, please always check the local laws in force.
DISPOSE OF THE PRODUCT RESPONSIBLY.
DISPOSING OF THE PRODUCT
Our products are made of various materials. Most of these materials (aluminium, plastic, iron and electrical cables) are classified as solid urban waste. They can be
separated for recycling and disposed of at authorised waste treatment plants.
Other components (electronic boards, transmitter batteries, etc.) may contain pollutants.
These must be removed and disposed of by an authorised waste disposal and recycling firm.
It is always advisable to check the specific laws that apply in your area.
DISPOSE OF THE PRODUCT RESPONSIBLY.

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PRODUCT DATA AND INFORMATION
Key
This symbol shows which parts to read carefully.
This symbol shows which parts describe safety issues.
This symbol shows what to tell users.
The measurements, unless otherwise stated, are in millimetres.
Description
803BB-0350
GPX40MGC - Automatic barrier with irreversible gearmotor and brushless motor; painted galvanised steel cabinet. Model suitable for areas exposed to high
temperatures.
Intended use
The ideal solution for passage ways with heavy transit flows
Any installation and/or use other than that specified in this manual is forbidden..
Usage limitations
MODELS GPX40MGC
Max. net clearance width (m) 3,8
Technical data
MODELS GPX40MGC
Power supply (V - 50/60 Hz) 100 AC to 240 AC
Motor power supply (V) 36 DC
Standby consumption (W) 2,5
Power (W) 270
Operating temperature (°C) -20 to +55 (-40 with item 803XA-0260)
Torque (Nm) 100
Opening time at 90° (s) 1 ÷ 2
Duty cycle (%) CONTINUOUS OPERATION
Protection rating (IP) 54
Insulation class I
Weight (kg) 62
Fuse table
MODELS GPX40MGC
Line fuse 3.15 A F
Accessory fuse 2 A F
Cartridge heater fuse -
Fan fuse 100 mA F

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Description of parts
Barrier
1Anti-shearing cover
2Fastening flange
3Boom anchoring plate
4Cabinet
5Inspection hatch
6Cover
7Boom release/lock knob
8Control panel
9Cushioned mechanical stop for boom adjustment (88003-0096)
10 Spring anchoring pin
11 Auxiliary
12 Anchoring plate
13 Anchoring bracket
14 Fuse for cartridge heater or fan
15 Fan
16 Line fuse
6
8
5
2
1
12
7
9
9
11
7
3
4
10
14
15
16
13

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Control board
1Programming buttons
2Display
3USB stick connector
4Encoder connector
5Motor connector
A p.n. ferrite ECQK922091 is applied to the cable
6Terminal board for barrier status
7Terminal board for connecting the warning LED strip
8Terminal board not used
9Accessories fuse
10 Terminal board for motor power supply
11 Terminal board for power supply to the control board
12 Terminal board for connecting the open cover safety microswitch (NC
contact)
13 Terminal board for NC contact for boom drop away
14 Terminal board for connecting the released gearmotor safety microswitch
(NC contact)
15 Terminal board associated with the RSE_2 connector for CRP connection, IO
485 card or Modbus RTU interface
16 Terminal board associated with the RSE_1 connector for paired, alternate or
CRP connection
17 Terminal board for connecting control and safety devices
18 Terminal board for connecting the keypad selector
19 Terminal board for connecting the transponder selector switch
20 Terminal board for connecting the antenna
21 Connector for the R700 or R800 decoding card
22 Connector for plug-in radio frequency card (AF)
23 RSE_1 connector for RSE card
24 RSE_2 connector for RSE card
25 Connector for the clock card (806SA-0120)
A B GND A B GND R G B
24
10
S1 GND AB
11 E1 E6 TS 1 2 3 3P 4 5 7 2 CX CY CZ 0300
TAMPER
FCA CM1 FCC CM2 EB
MOTOR
BLOCK ARM
EB+
2
14 13 12 11 10
3 544
6
7
8
9
1
15
16
20 19 18 17
24
23
22
25
21

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Size
326 max 3800
270
884
1174
374,5
244
Cable types and minimum thicknesses
CABLE LENGTH (m) < 10 10 to 20 from 20 to 30
Power supply 230 V AC 3G x 1.5 mm² 3G x 1.5 mm² 3G x 2.5 mm²
24 V AC - DC Flashing beacon 2 x 1 mm² 2 x 1 mm² 2 x 1 mm²
TX Photocells 2 x 0.5 mm² 2 x 0.5 mm² 2 x 0.5 mm²
RX photocells 4 x 0.5 mm² 4 x 0.5 mm² 4 x 0.5 mm²
Command and control devices *no. x 0.5 mm² *no. x 0.5 mm² *no. x 0.5 mm²
Antenna RG58 max 10 m
* no. = see product assembly instructions - Warning: the cable cross-section is indicative and varies according to the motor power and cable length.
For installation in an outdoor environment, use cables with properties at least equivalent to those of type H05RN-F (with designation 60245 IEC 57).
For installation in an indoor environment, use cables with properties at least equivalent to those of type H05VV-F (designation to 60227 IEC 53).
If the cable lengths differ from those specified in the table, define the cable cross-sections according to the actual power draw of the connected devices
and in line with regulation CEI EN 60204-1.
For multiple, sequential loads along the same line, recalculate the values in the table according to the actual power draw and distances. For information
on connecting products not covered in this manual, please see the documentation accompanying the products themselves.
For paired and CRP connection, use a UTP CAT5 cable. Maximum length 1000 metres.
Wind resistance
The table shows the boom wind-load resistance.
Resistance class with reference to the EN 13241 standard.
Type Boom 2.25 m Boom 3.05 m Boom 4.05 m
Resistance class 5 4 3
Wind pressure [Pa] 1200 1000 800
Maximum wind speed [km/h] 144 132 118

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INSTALLATION
The following illustrations are examples only. The space available for fitting the operator and accessories varies depending on the area where it is
installed. It is up to the installer to find the most suitable solution.
In case of manual handling, have one person for every 20 kg that needs hoisting; for non-manual handling, use proper hoisting equipment in safe conditions.
When the operator is being fixed in place, it may be unstable and overturn. Be careful and do not lean on it until it is fully fastened in place.
Preliminary operations
If the flooring does not allow the device to be fastened in a solid and stable way, lay a cement slab.
Dig a hole for the foundation frame.
Set up the corrugated tubes needed for the wiring coming out of the junction pit.
The number of tubes depends on the type of system and the accessories that are going to be fitted.
265
200
220
145
400
700
500
Laying the anchoring plate
Set up a foundation frame that is larger than the anchoring plate.
Fit an iron cage in the foundation frame to reinforce the concrete.
Assemble the anchoring braces to the plate.

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Fit the anchoring plate in the iron cage.
The tubes must pass through the existing holes.
Cast cement into the foundation frame.
The plate must be perfectly level and the screw threads completely above surface.
Wait at least 24 hours for the cement to dry.
Remove the foundation frame.
Fill the hole with soil around the concrete block.
Remove the nuts from the screws.
Thread the electrical cables into the tubes so that they protrude by about 1500 mm.
Preparing the barrier
With the cover open, the operator does not work.
1
2
3
4

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Fastening the barrier

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Changing the boom opening direction
The barrier is set up for installation on the left.
The direction of rotation must be changed without the boom and
spring installed.
1Remove the anchoring pin from the lever arm
2Release the gearmotor turning the knob clockwise.
3Turn the lever arm by 90°.
4Lock the gearmotor turning the knob anticlockwise.
5Fasten the anchoring pin to the opposite hole on the lever arm.
The hole to which fasten the anchor pin also depends on the balance
spring chosen according to the boom length. Please see the section
[Choosing the balance spring and fastening hole].
6Removes the boom anchoring plate
7Turn the boom anchoring plate 90°
8Fasten the boom anchoring plate to the crankshaft plate
DX SX
1 2 3 4 5
6 7 8

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Boom installation
Install the boom-attachment cover on the anchoring plate. Leave the screws slightly loose for easier fitting of the boom later.
Insert the reinforcement inside the boom.
Fit the boom into the fastening flange.
Tighten the screws firmly.
Drill the fastening flange.
Fasten the boom with the screws.
Ø 4UNI6954
4.8x13

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1Cut the slot-cover profiles to the same size as the boom slot minus 10 millimetres.
2Insert the slot-cover profiles into the grooves on both sides of the boom.
5Cut the excess part of the profile, leaving a 7 mm overhang.
4Insert the anti-impact rubber profile into the groove, aligning it with the end cap.
3Fit the rubber end cap in position.
6Insert the rubber profile end cap into the groove in the boom closing cap. Use the screws to fasten the boom end cap.
7Fit the anti-shearing protective cover onto the boom-attachment cover and fasten it using the screws supplied.
⚠
1 2
345
67
Choosing balance spring and fastening hole
Spring code (colour) 001G02040 Ø 40 mm (yellow) 001G04060 Ø 50 mm (green)
Hole to which fasten the spring A B A B
Passage width clearance (m) from 1.5 to 1.75 from 1.75 to 2.25 from 2.25 to 2.75. from 2.75 to 3.75.
Simple boom means the boom complete with slot cover, cap and rubber profile.
B
A

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Assembling the balance spring
1Release the gearmotor.
2Position the boom vertically.
3Lock the gearmotor
4Tighten the eyelet tie rod to the lower part of the spring.
5Screw the spring to the anchoring pin.
6Hook the eyelet rod onto the anchoring bracket.
3
2
1
4
5
6

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Balancing the boom
1Release the gearmotor.
2Manually turn the spring to increase or reduce the traction. The boom
should stabilise at 45°.
3Fasten the locknut.
Position the boom vertically.
4Lock the gearmotor
Check the proper working state of the spring. When the boom is vertical,
the spring is not taut. When the boom is horizontal, the spring is taut.
45°
4
1
2
3

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Determining the travel end points with mechanical limit switches
Check that the boom is parallel to the road surface when it is in the closed position and at about 89° when it is in the open position.
Correct the boom’s horizontal position
Release the gearmotor.
Open the inspection hatch.
Lower the boom.
1Turn the cushioned mechanical stop until you reach the desired boom position.
2Fix the cushioned mechanical stop with a locknut.
Lock the gearmotor
+
_
2
1
1

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Correct the boom’s vertical position
Release the gearmotor.
Open the inspection hatch.
Raise the boom.
1Turn the cushioned mechanical stop until you reach the desired boom position.
2Fix the cushioned mechanical stop with a locknut.
Lock the gearmotor
+_
~1°
~89°
1 1
2

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ELECTRICAL CONNECTIONS
Passing the electrical cables
The electrical cables must not touch any parts that may overheat during use (such as the motor and transformer).
Make sure that the moving mechanical parts are suitably far away from the wiring.
Power supply
Make sure the mains power supply is disconnected during all installation procedures.
Before working on the control panel, disconnect the mains power supply and remove the batteries, if any.
Connecting to the electrical network
1Button for turning the device on/off.
2Apply the ferrite supplied to the power supply cable.
Ferrite type p.n. ECQK922091.
The cable must pass through the ferrite twice (2 turns).
3Connect the power cable as shown.
4Fuse for cartridge heater or fan
5Line fuse
Power supply output for accessories
The output normally delivers 24 V DC.
The sum of the power draw for the connected accessories must not
exceed 40 W.
LN
2 3
5
1
410 11 E1 E6 TS 1 2 3 3
P
E1
E6
T
S
1
2
3
3P

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Maximum capacity of contacts
Device Output Power supply (V) Power (W)
Accessories 10 - 11 24 DC 40
Additional light 10 - E1 24 DC 20
Flashing beacon 10 - E1 24 DC 20
Operator status warning light 10 - 5 24 DC 3
RGB LED strip - - 13,5
The sum of the power draw for the connected accessories must not exceed 40 W.
Command and control devices
1Antenna with RG58 cable
2Card reader
3Transponder selector switch
4Keypad selector
5STOP button (NC contact)
This stops the boom and excludes automatic closing. Use a control device to resume movement.
If the contact is not used, it must be deactivated during programming.
6Control device (NO contact)
OPEN ONLY function
When the [HOLD-TO-RUN] function is active, the control device must be connected during OPENING.
7Control device (NO contact)
OPEN ONLY function
The contact must only be used for operators working in paired mode.
8Control device (NO contact)
CLOSE ONLY function
When the [HOLD-TO-RUN] function is active, the control device must be connected during CLOSING.
9Control device (NO contact)
OPEN-CLOSE function
2
24
10
S1 GND AB
11 E1 E6 TS 1 2 3 3P 4 5 7 2 CX CY CZ
FA FC STB TAMPER
+
-
32
1
4 6 7 8 9
5