CAME ZG5 User manual

ZG5
INSTALLATION MANUAL
AF
ZG 5
COMMAND BOARD PLUS FOR BARRIERS
WITH 230V MOTOR

2
All the data and information contained herein is considered subject to change at any time and at our discretion
ENGLISH
4.1 Command board
1 Legend
This symbol indicates sections to be read with particular care.
This symbol indicates sections concernig safety
This symbol indicates notes to communicate to users.
Fully designed and built by CAME CANCELLI AUTOMATICI S.p.A. Guaranteed for 24 months unless tampered with.
The command board is powered at 230V A.C. on the L-N terminals with 50÷60 Hz frequency and is protected in input with 5A
fuse.
A 2A fuse protects the low voltage (24V) command devices.
630mA control unit fuse. 1.6A electrical locking fuse.
The overall rated power of the 24V accessories must not exceed 40 W.
The board manages an operating time of 20 seconds, which protects in the case that the end stop unit does not intervene.
Possibility of inserting the RSE board to enable the compass function or paired with dip (1 ON = compass, 2 ON = paired).
The photoelectric cells may be connected and pre-set for:
- Re-opening during closing phases: if the photocells identify an obstacle while the gate is closing, they will reverse the direc-
tion of movement until the gate is completely open;
- Total stop: stops the bar with consequent exclusion of the automatic closing cycle; pushbuttons or transmitters must be used
to resume movement.
The board also integrates and independently manages a safety function which is sensitive to the obstacles (encoder) that:
during opening: the bar inverts its direction until it is completely close,
during closure: the bar inverts its direction until it is completely open.
Caution! after three consecutive direction reversals, the bar will remain up and automatic closure will be discontinued. To
close the gate, use the radio remote control or the push-button.
Other selectable functions:
- Automatic closure. The automatic closure timer self-powers at the end stop in opening. The set time can be adjusted and is
also subject to modifications due to the intervention of additional safety features. This does not happen following a complete
“stop” command or if there be a power cut;
- Immediate closure: The bar lowers automatically after the vehicle has exceeded the range of action of the safety devices;
- Obstacle detection: this function voids every command if an obstacle is detected by the photoelectric cells (connected to any
safety function);
- Maintained action operations: barrier operation while keeping the pushbutton pressed (it excludes the radio transmitter ope-
ration);
- Pre-flashing during opening and closing: after an opening or closing command, the flashing lamp connected to 10-E, flashes
for 5 seconds before the manoeuvre begins;
- Type of command: open-close or opening only
Settings: automatic closure time adjustment.
4 Description
“IMPORTANT SAFETY INSTRUCTIONS FOR INSTALLATION”
“CAUTION: IMPROPER INSTALLATION MAY CAUSE SERIOUS DAMAGE, FOLLOW ALL INSTALLATION INSTRUCTIONS CAREFULLY”
“THIS MANUAL IS ONLY FOR PROFESSIONAL INSTALLERS OR QUALIFIED PERSONS”
2.1 Destination
The following standard were complied with for this product: EN 12978, UNI EN 954-1, CEI EN 60335-1, UNI EN 12453.
2 Destination and limits of use
The electronic command board was designed for specific use in automatic GARD 4 and GARD 8 series barriers with 230V
gear motors; inserted into the container fitted with a transformer with IP54 protection level, 230V power supply with 50÷60
Hz frequency.
Uses other than the ones described above and installations using methods other than those shown in this technical
manual are considered prohibited.
3 Standard followed
2.2 Limits of use
Comply with the cable cross-sections recommended in the table under chapter 5.3.

3
All the data and information contained herein is considered subject to change at any time and at our discretion
ENGLISH
Power supply: 230V / 50÷60 Hz.
Maximum power allowed: 400W
Absorption at rest: 25W
Maximum power for 24V accessories: 20W
Maximum power for 230V accessories: 200W
Insulation type:
Material case: ABS
#
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4.2 Technical information
4.3 Main components
1 - 5 A mains fuse
2 - 630 mA fuse control assembly
3 - 2 A accessories fuse
4 - 1.6 A electric lock fuse
5 - Supply-connecting terminal board
6 - Transformer-connecting terminal board
7 - Electric lock-connecting terminal board
8 - End-stop assembly-connecting terminal board
9 - Combined barriers connecting terminal board
10 - Encoder-connecting terminal board
Optional accessories:
- flashing dome signals the bar in motion;
- lighted cord signals the bar closed or in motion; it turns off only if the bar is at an end stop and opens.
- bar open light marks the position of opening of the bar; it turns off after the closing operation.
Caution: Switch off the mains prior to any inspection or maintenance work on the equipment.
11 - Connecting terminal boards
12 - radiofrequency board coupling (see table page 9)
13 - RSE serial board coupling (optional for connection of
combined and/or interlock barriers)
14 - ACT Trimmer: automatic closure time adjustment
15 - “function selection” dipswitch
16 - Code saving buttons
17 - radio code / automatic closing flashing LED indicator
18 - manoeuvre counter
19 - Motor terminal board
5
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6
13
12
11
10
Black
Brown
Brown
Black
Blue
Red
Orange
White
Black Red
17
14
2
6
White
Red
5
7
19
Blue Violet Orange
4
Grey

4
All the data and information contained herein is considered subject to change at any time and at our discretion
ENGLISH
Before proceeding with the installation, it is necessary to:
- provide for suitable omnipolar disconnection device with more than 3 mm between contacts to section power supply;
- connections inside the case made for protection circuit continuity are allowed as long as they include additional insulation
with respect to other internal drive parts;
-make sure the mains voltage is disconnected.
5.3 Cable list and minimun thickness
Make sure all tools and materials necessary are within reach to install the edge in maximum safety, according to regulations in
force. The following figure illustrates the minimum equipment for the installer.
5.2 Tools and materials
Connections Type of cable Length of
cable 1<10 m Length of cable 10<20 m Length of cable 20<30 m
230V 2F power supply line
FROR CEI 20-22
CEI EN 50267-2-1
3G 1,5mm² 3G 2,5mm² 3G 4mm²
230V motor 3G 1mm² 3G 1,5mm² 3G 2,5mm²
230V courtesy / cycle light 3G 0,5mm² 3G 1mm² 3G 1,5mm²
24V power supply accessory 2 x 0,5mm² 2 x 0,5mm² 2 x 1mm²
24V pilot light 2 x 0,5mm² 2 x 0,5mm² 2 x 1mm²
24V “in motion” output 2 x 0,5mm² 2 x 0,5mm² 2 x 1mm²
Safety contacts 2 x 0,5mm² 2 x 0,5mm² 2 x 0,5mm²
N.O./N.C. control button 2 x 0,5mm² 2 x 0,5mm² 2 x 0,5mm²
End stop 3 x 0,5mm² 3 x 1mm² 3 x 1,5mm²
Command 2nd combined motor 1 x 0,5mm² 1 x 0,5mm² 1 x 1mm²
Antenna connection RG58 max. 10 m
N.B.: An evaluation of the size of the cables with lengths other than the data in the table must be made based on the effective
absorption of the connected devices, according to the instructions indicated by the CEI EN 60204-1 standards.
For connections that require several loads on the same line (sequential), the size given on the table must be re-evaluated based
on actual absorption and distances.
5 Installation
5.1 Preliminary checks

5
All the data and information contained herein is considered subject to change at any time and at our discretion
ENGLISH
U
VW
FC
FAF
ON
2
1345678910
EB EB VS CT L2T L1T INTERBLOCCO
NL
GND
BA D E+ VB 24 12 0
10 11 E6 E7 TS 1233P 457C1 C5
G4041
G4041I
White
Red
Orange
White
Condenser
M
Red Black Brown
Brown
Black
Blue
G2081
G2081I
Orange
Grey
Blue
Violet
5.4 Installing the electrical card
1) Unscrew the four
mounting screws (or three
in the case of the G4041) of
the cover of the container
located on the upper part of
the automation.
2) Insert the card into the container and fasten
it with the screws supplied.
3) Connect the terminal
boards of the transformer
housed in the container to the
command board.
Opening limit
switch
Closure limit
switch
:,

6
All the data and information contained herein is considered subject to change at any time and at our discretion
ENGLISH
(Condenser)
5.5 Electrical connections
10
E7
L
N
+10
-11
1
2
2
3
U
W
V
2
C1
10
5
F
FA
2
C5
F
FC
2
7
230V (a.c.) power supply
230V(a.c.) motor
Flashing dome 24V (A.C.) max.8W, signals the bar in motion
24V (A.C.) max. 30W supply accessories
Stop pushbutton (N.C.)
Open pushbutton (N.O.)
Command pushbutton (see dip-switch 2 in function selections)
Contact (N.C.) of «reopening during closing»
Pilot light indicating “barrier open” (24V-3W max.)
Contact (N.O.) of «immediate closing»
Open end stop connection (N.C.)
Close end stop connection (N.C.)
IF NOT USED
IF NOT USED
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U
VW
FC FA F
EB
EB
N
LVSCTL2T
L1T
M
10
E6 Cord signals 24V (A.C.) max. 24W, signals the bar closed or in motion, it turns off
only if the bar is in open end stop mode
2
3P Opening pushbutton (N.O.) for combined and/or bush function
2
4Closing pushbutton (N.O.)
Antenna connection
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7
All the data and information contained herein is considered subject to change at any time and at our discretion
ENGLISH
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Allows the control assembly to check the efficiency of the safety de-
vices (photoelectric cells) after each opening or closing command.
A possible photoelectric cell malfunction is identified with via LED
indicator flashing on the control panel, consequently cancelling any
remote control or pushbutton commands.
Electrical connection for safety test activation:
- photoelectric cell transmitters and receivers must be connected in
the following way (see scheme)
-turn dip-switch 8 to ON to carry out the test.
IMPORTANT:
when carrying out the safety test function, contacts N.C. if not used,
on the relative dip switches (see functions selection p. 8)
5.6 Photoelectric cells performance test
EB
EB
5.7 Gearmotor end-stop connection
Gearmotor end-stop assembly already connected for
installation on the left-hand side seen from inside.
FA FC
NC NC
COM
FUW
M
V
FA FC
NC
NC
COM
FUW
M
V
For right-hand installation:
- reverse FA-FC of the end stops on the terminal board;
- reverse the U-V phases of the motor on the terminal board.
Output supplied for
electric lock (comes
on with the opening
command)
6
6
- VB1 (shifted) supplied for
electric lock a 12V
- VB2 (preset) supplied for electric
lock a 24V
5.8 Motor torque limiter
To alter the torque, move the fast-on (marked with black string) to one
of the 4 remaining positions: 1 min ÷ 4 max.

8
All the data and information contained herein is considered subject to change at any time and at our discretion
ENGLISH
G2081
G2081I G4041
G4041I
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 
/.
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ON
OFF
A.C.T Trimmer = min. automatic closing
time 1 sec, max. 120 sec.
5.10 Adjustments
5.9 Function selections 1 ON Automatic closing function activated; (1 OFF-deactivated);
2 ON “Open” function with activated remote control (HF board inserted);
2 OFF “Open-close-reverse” function with pushbutton (2-7) and activated remote con-
trol (HF board inserted) ;
3 ON “Maintained Action” function (remote control function disabled) activated; (3 OFF
deactivated);
4 ON Activated pre-flashing during opening and closing,, with device connected on ter-
minals 10- E7 (4 OFF deactivated);
5 ON Obstacledetection.Withthemotoroff(barclosed,openorafteratotal-stopcom-
mand), movement is blocked if safety devices (e.g. photoelectric cells) detect an
obstacle;
6 OFF Total stop function activated, connect pushbutton to 1-2 (if not set the dipswitch
to ON);
7 OFF Reopening function during closure activated, connect the safety devices to termi-
nals 2-C1 (if not used set the dipswitch to ON);
8 ON Safety test function to check photoelectric cell efficiency (page.7) activated; (8
OFF deactivated).
9 OFF Encoder activated for obstacle detection (9 ON deactivated);
10 Not used
5.12 Operation counter
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 
Counts the number of operations
displayed with the 8 LED to zero
out the count, position the dip 1 to
OFF (if selected to ON) and the dip
3 to ON, press the CH1 and wait
for all the LED to turn off. After
zeroing out, return the dip 1 to ON
(if selected) and dip 3 to OFF.
Led n°1 = 5000 manoeuvres
Led n°2 = 10000 manoeuvres
Led n°3 = 25000 manoeuvres
Led n°4 = 50000 manoeuvres
Led n°5 = 100000 manoeuvres
Led n°6 = 250000 manoeuvres
Led n°7 = 500000 manoeuvres
Led n°8 = 1000000 manoeuvres
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5.11 Management of the manoeuvre pick-up function
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 
To manage the manoeuvre pick-up function,
position the dip 1 and dip 3 to ON; all 8 LED of the
manoeuvre counter will be on (default memorization
for G2081 and G2081I); to select management of
manoeuvre pick-up function for G4041 e G4041I
barriers, position the dip 1 and 3 to ON and
press the CH1 button. The first 4 LEDs will be on.
Reposition the dip 3 to OFF and dip 1 can be left on
the ON position, if automatic closure is desired.
/.
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

9
All the data and information contained herein is considered subject to change at any time and at our discretion
ENGLISH
/.
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2) The AF board should ALWAYS be inserted
when the power is off.
1) On AM transmitters operating at 433.92 MHz (TOP
and TAM series), position the jumper connection on
circuit card AF43S as shown on the sheet.
Frequency/MHz Radiofrequency board Transmitter
FM 26.995 AF130 TFM
FM 30.900 AF150 TFM
AM 26.995 AF26 TOP
AM 30.900 AF30 TOP
AM 433.92 AF43S / AF43SM TAM / TOP
AM 433.92 AF43SR ATOMO
AM 40.685 AF40 TOUCH
Standard encoding procedure T262M - T264M - T2622M - T302M - T304M - T3022M
1 assign a code (also on file)
2 connect encoding jumper J
3 register code
4 disinserire jumper J
TOP TAM
/.
/&&
0
0
Press P1 or P2 in sequence in order to register the
code; at the tenth pulse, a double beep will confirm
that registration has occurred
“AF” board
Mother board
TOP QUARZATI SERIES
Read the three steps below before beginning installation procedures:
- prepare the radio board (paragraph 6.1);
- procedure for codifying the transmitter (paragraph 6.2);
- memorizing the code on the command board (paragraph 6.3).
6.1 Prepare the radio board (AF)
6 Installation procedure of the transmitter for remote control
6.2 Procedure for codifying the transmitter

10
All the data and information contained herein is considered subject to change at any time and at our discretion
ENGLISH
0 0
The first encoding operation must be carried out whilst keeping the jumpers po-
sitioned for channels 1 and 2 as per fig. A; see fig. B for any subsequent settings
on different channels.
TOP
T262M - T302M
FIG.A FIG.B
0 0
0 0
T264M - T304M
0 0
0 0
/.
/&&
0
0
T2622M - T3022M
P1 = CH1
P2 = CH2
P3 = CH3
P4 = CH4
P1 = CH1
P2 = CH2
P1 = CH1 - P2 = CH3 P1 = CH3 - P2 = CH2
P1 = CH1 - P2 = CH4 P1 = CH3 - P2 = CH4
1° Code
P1 = CH1
P2 = CH2
2° Code
P3 = CH1
P4 = CH2

11
All the data and information contained herein is considered subject to change at any time and at our discretion
ENGLISH
        
   
0 0
               
/. /. /. /.
               
/. /. /. /.
TOP
T432M - T312M
set the code to dip-switch C and channel to D (P1=CH1 and P2=CH2, default setting)
D
C
P1
P2
CH1 CH2 CH3 CH4
CH1 CH2 CH3 CH4
TOP
T434M - T314M
        
0 0
0 0
C
set code only
P1 = CH1
P2 = CH2
P3 = CH3
P4 = CH4
TOP
T432S - T432SA - T434MA - T432NA - T434NA
see instructions on pack
TAM
T432 - T434 - T438 - TAM432SA
see instruction
sheet inside the
pack
TFM
T132 - T134 - T138
T152 - T154 - T158
see instruction sheet inside the
pack
CAME
AT01 - AT02 - AT04
see instruction sheet inside the pack of
AF43SR circuit card
CAME
TCH 4024 - TCH 4048
see instructions on pack
TOUCH SERIES
TOP SERIES
ATOMO SERIES

12
All the data and information contained herein is considered subject to change at any time and at our discretion
ENGLISH
#
#
2) Press a transmitter key to send the code; the LED will remain
lighted to signal memorization.
Follow the same procedure with the “CH2” key, again using another
transmitter key.
Flashing LED
Lit LED
Radiofrequency
board
1
2
ZL38





2
1
3
G2081
G2081I G4041 G4041I
CH1 = Channel for direct commands with a gearmotor control
assembly function of “open only” or “open-close-reverse”, depend-
ing on the selection carried out on dip-switches 2).
CH2 = Channel for direct commands with an accessory device (radio control with combined barrier connection or with bush).
N.B.: if desired, simply repeat the sequence described to change the code.
CH1
CH2
6.3 Memorizing the code on the command board
1) Keep the "CH1" key pressed on the base card, the
signal LED will flash.
2) Insert the inspection door and close it.
1) After making the adjustments
and settings from the command
board, insert the lid of the
container and close it with the
screws.
6.4 Mounting the lid
3) Insert the protection dome on the upper
part of the automation (for the GARD4
fasten it on the side with two UNI6954
Ø3.9x13 screws supplied.

13
All the data and information contained herein is considered subject to change at any time and at our discretion
ENGLISH
In its premises, CAME CANCELLI AUTOMATICI S.p.A. implements an Environmental Management System certified in
compliance with the UNI EN ISO 14001 standard to ensure environmental protection.
Please continue our efforts to protect the environment—which CAME considers one of the cardinal elements in the development
of its operational and market strategies—simply by observing brief recommendations as regards disposal:
DISPOSAL OF PACKAGING – The packaging components (cardboard, plastic, etc.) are all classifiable as solid urban waste
products and may be disposed of easily, keeping in mind recycling possibilities.
Prior to disposal, it is always advisable to check specific regulations in force in the place of installation.
PLEASE DISPOSE OF PROPERLY!
PRODUCT DISPOSAL – Our products are made up of various types of materials. Most of them (aluminium, plastics, iron,
electrical wires, etc.) may be disposed of in normal garbage collection bins and can be recycled by disposing of in specific re-
cyclablematerialcollectionbinsanddisposalinauthorizedcentres.Othercomponents(electricalboards,remotecontrolbatteries,
etc.), however, may contain polluting substances. They should therefore be removed and given to qualified service companies for
proper disposal.
Prior to disposal, it is always advisable to check specific regulations in force in the place of disposal.
PLEASE DISPOSE OF PROPERLY!
7 Demolition and disposal
MANUFACTURER’S DECLARATION OF CONFORMITY
Pursuant to annex II B of the Machinery Directive 98/37/EC
CAME Cancelli Automatici S.p.A.
via Martiri della Libertà, 15
31030 Dosson di Casier - Treviso - ITALY
tel [phone] - fax [phone]
internet: www.came.it - e-mail: inf[email protected]
Declares under its own responsibility that the equipments for automatic garage doors and
gates listed below:
… comply with the National Law related to the following European Directives and to the
applicable parts of the following Standards.
98/37/CE - 98/79/CE MACHINERY DIRECTIVE
98/336/CEE - 92/31/CEE ELECTROMAGNETIC COMPATIBILITY DIRECTIVE
73/23/CEE - 93/68/CE LOW VOLTAGE DIRECTIVE
89/106/CEE CONSTRUCTION PRODUCTS DIRECTIVE
EN 13241-1 EN 12635 EN 61000-6-2
EN 12453 EN 12978 EN 61000-6-3
EN 12445 EN 60335-1 EN 60204-1
IMPORTANTWARNING!
Do not use the equipment specified here above, before completing the full installation
In full compliance with the Machinery Directive 98/37/EC
MANAGING DIRECTOR
Mr. Andrea Menuzzo
8 Manufacturer’s warranty
Reference code to request a true copy of the original: DDF B EN G001 ver.1.0
ZG5 ELECTRONIC COMMAND BOARD

Cod. 319T47 ver. 1.3 06/06 © CAME CANCELLI AUTOMATICI
CAME UNITED KINGDOM LTD
UNIT 3, ORCHARD BUSINESS PARK TOWN
STREET, SANDIACRE
NOTTINGHAM - NG10 5BP - U.K.
Tel [phone]
Fax [phone]