CAME ZL65 User manual

ZL65
INSTALLATION MANUAL
FA0 1 3 59- E N
EN English

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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 has been designed to be assembled
to partly completed machinery and/or equipment so as to build machinery as
regulated by the Machinery Directive 2006/42/EC. • 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. • All the components (e.g.
actuators, photocells and sensitive edges) needed for the final installation to comply
with the Machinery Directive (2006/42/EC) and with the reference harmonised
technical standards are specified in the general CAME product catalogue or on the
website www.came.com. • Check that the temperature ranges given are suitable
for the installation site. • 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-o device along the power supply that is compliant with
the installation rules. It should completely cut o the power supply according to
category III surcharge conditions. • Demarcate the entire site properly to prevent
unauthorised personnel from entering, especially minors. • Use suitable protection
to prevent any mechanical hazards due to persons loitering within the operating
range of the operator.

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• The electrical cables must pass through special pipes, ducts and cable glands
in order to guarantee adequate protection against mechanical damage. • The
electrical cables must not touch any parts that may overheat during use (such
as the motor and transformer). • Before installation, check that the guided part
is in good mechanical condition, and that it opens and closes correctly. • The
product cannot be used to automate any guided part that includes a pedestrian
gate, unless it can only be enabled when the pedestrian gate is secured. • Make
sure that nobody can become trapped between the guided and fixed parts, when
the guided part is set in motion. • 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 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 axed 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 sta, 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.
DISMANTLING AND DISPOSAL

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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
002ZL65
Control panel for one or two-leaf swing gates, with programming display, on-board radio decoding and self-diagnosing safety
devices.
Technical data
MODELS ZL65
Power supply (V - 50/60 Hz) 230 AC
Motor power supply (V) 24 DC
Board power supply (V) 24 AC
Standby consumption (W) 7
Standby consumption with the RGP1 (W) module 0,5
Power (W) 300
Colour RAL 7035
Operating temperature (°C) -20 ÷ +55
Operating time (s) 180
Duty cycle HEAVY-DUTY SERVICE
Protection rating (IP) 54
Insulation class II
Fuse table
MODELS ZL65
Line fuse 2 A F
Accessory fuse 2 A F

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Description of parts
1Transformer
2Line fuse
3Power supply terminal board
4Terminal board for connecting the signalling devices
5Terminal boards for gearmotors with encoder
6Terminal board for connecting control devices
7Terminal board for connecting the safety devices
8Terminal board for CRP connection
9Terminal board for connecting the transponder selector
switch
10 Terminal board for connecting the keypad selector
11 Terminal board for connecting the antenna
12 Connector for the UR042 module
13 Connector for plug-in radio frequency card (AF)
14 Connector for the R700 or R800 decoding card
15 RIO CONN card connector
16 RSE card connector
17 Memory Roll card connector
18 Programming buttons
19 Display
20 Housing for UR042 module
21 Housing for the RGP1 module
22 Housing for the RLB card
23 Terminal board for connecting the RGP1 module
24 Accessories fuse
26
00
230
17
120
10 TS 2 CX CY

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Size
254
274
184 204 133
Cable types and minimum thicknesses
Cable length (m) up to 20 from 20 to 30
Power supply 230 V AC 3G x 1.5 mm² 3G x 2.5 mm²
24 V AC/DC flashing beacon 2 x 0.5 mm² 2 x 0.5 mm²
TX Photocells 2 x 0.5 mm² 2 x 0.5 mm²
RX photocells 4 x 0.5 mm² 4 x 0.5 mm²
12 V DC electric lock 2 x 1 mm² 2 x 1.5 mm²
Command and control devices *no. x 0.5 mm² *no. x 0.5 mm²
* no. = see product assembly instructions
Warning: the cable cross-section is indicative and varies according to the motor power and cable length.
When operating at 230 V and outdoors, use H05RN-F cables compliant with 60245 IEC 57 (IEC); when operating
indoors, use H05VV-F cables compliant with 60227 IEC 53 (IEC). For power supplies up to 48 V, you can use FROR
20-22 II cables compliant with EN 50267-2-1 (CEI).
To connect the antenna, use RG58 cable (up to 5 m).
To connect to the CRP, use a UTP CAT5 cable (up to 1,000 m long).
If the cable lengths dier 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.
To connect the encoder, use a FROHE 300/500 V shielded cable (3 x 0.5 mm²).

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INSTALLATION
Preparing the control panel
1Separate the parts of the control panel.
2Drill the pre-marked holes. The diameter of the holes is 20 mm.

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Fastening the control panel
1Drill the fixing points in the control panel in a protected area.
2Fasten the base using screws and plugs.
Use Phillips round head screws (maximum diameter 6 mm).
3Insert the cable gland with the corrugated tubes for threading the electrical cables
254
184

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ELECTRICAL CONNECTIONS
Preparing the electrical cables
Connect all wires and cables in compliance with the law.
Use cable glands to connect the devices to the control panel. One of these must be used exclusively for the
power supply cable.
26
00
230
17
120

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Power supply
1Connecting to the mains (120/230 V AC - 50/60 Hz)
2Power supply output for accessories
The output normally delivers 24 V AC.
The output delivers 24 V DC when the batteries start operating, if they are installed.
10 11 E 5
Maximum capacity of contacts
Device Output Power supply (V) Power (W)
Accessories 10 - 11 24 AC/DC 25
Flashing beacon 10 - E 24 AC/DC 25
Operator status warning
light 10 - 5 24 AC/DC 3
The sum of the power draw for the connected accessories must not exceed 50 W.
Gear motor with encoder
1Gearmotor delayed while opening
2Gearmotor delayed while closing
M1 N1 ENC1 M2 N2 ENC2
N
E
M
M
N
E

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Command and control devices
1STOP button (NC contact)
Stop the gate and exclude automatic closing. Use a control device to resume movement.
If the contact is not used, it must be deactivated during programming.
2Control device (NO contact)
PARTIAL OPENING function
PEDESTRIAN OPENING function
OPEN ONLY function
See function [F8] command 2-3P.
3Control device (NO contact)
OPEN-CLOSE function
OPEN-STOP-CLOSE-STOP function
OPEN ONLY function
CLOSE ONLY function
See function [F7] command 2-7.
4Card reader
5Transponder selector switch
6Keypad selector
7Antenna with RG58 cable
1 2 3P 7 A B
S1 GND
7

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Signalling devices
During programming, configure the type of action that must be performed by the device connected to the output.
1Flashing beacon
It flashes when the operator opens and closes.
See function [F18] additional light.
2Additional light
It increases the light in the manoeuvring area.
See function [F18] additional light.
3Operator status warning light
It notifies the user of the operator status.
See function [F10] open warning light or enable electric lock.
4Connection for the 12 V AC electric lock - 15 W max.
See function [F10] open warning light or enable electric lock.
Replace the 2 A accessories fuse with a 3.15 A fuse.
5Resistance 6.8 Ω - 7 W
10 11 E 5

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Safety devices
During programming, configure the type of action that must be performed by the device connected to the input.
Connect the safety devices to the CX and/or CY inputs.
If contacts CX and/or CY are not used, they must be deactivated during programming.
DELTA photocells
Standard connection
DELTA photocells
Connection with safety test
See function [F5] Safety devices test.
+-
NO C NC +-
RX TX
10 11 E 5
10 TS 2 CX CY
NO C NC RX TX
10 11 E 5
10 TS 2 CX CY
+- +-
DIR / DELTA-S photocells
Standard connection
DIR / DELTA-S photocells
Connection with safety test
See function [F5] Safety devices test.
+
10
-
2TXCNC TX 2
RX TX
10 11 E 5
10 TS 2 CX CY
+
10
-
2TXCNC TX 2
RX TX
10 11 E 5
10 TS 2 CX CY

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DXR photocells
Standard connection
DXR photocells
Connection with safety test
See function [F5] Safety devices test.
RX TX
10 11 E 5
10 TS 2 CX CY
10 11 OUT 10 11 SY
10 11 E 5
10 TS 2 CX CY
RX TX
10 11 OUT 10 11 SY
DFWN sensitive edge
CNONC
DFWN
10 TS 2 CX CY

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PROGRAMMING
Programming button functions
1ESC button
The ESC button is used to perform the operations described below.
Exit the menu
Delete the changes
Go back to the previous screen
2< > buttons
The <> buttons are used to perform the operations described below.
Navigate the menu
Increase or decrease values
3ENTER button
The ENTER button is used to perform the operations described below.
Access menus
Confirm choice
During movement, outside the menu, the ESC key stops the gate and the <> keys open and close the gate.
Getting started
Once the electrical connections have been made, proceed with commissioning. Only skilled and qualified sta
may perform this operation.
Make sure that there are no obstacles in the way.
Start programming with the functions indicated below.
A1 Motor type
F46 Number of motors
A3 Travel calibration
Complete programming and check the warning and safety devices are working properly.
After powering up the system, the first manoeuvre is always to open the gate Wait for the manoeuvre to be
completed.
Press the ESC button or STOP button immediately in the event of any faults, malfunctions, strange noises or
vibrations, or unexpected behaviour in the system.
Functions menu
Total stop
Stop the gate and exclude automatic closing. Use a control device to resume movement.
F1 Total stop OFF (Default)
ON

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CX input
Associate a function with the CX input.
The parameter [C3] appears only if the [Automatic closing] function is active
F2 CX input OFF (Default)
C1 = Reopen while closing (photocells)
C2 = Reclose while opening (photocells)
C3 = Partial stop Only with [Automatic
close] activated.
C4 = Obstacle standby (photocells)
C7 = Reopen while closing (sensitive
edges)
C8 = Reclose while opening (sensitive
edges)
CY input
Associate a function with the CY input.
The parameter [C3] appears only if the [Automatic closing] function is active
F3 CY input OFF (Default)
C1 = Reopen while closing (photocells)
C2 = Reclose while opening (photocells)
C3 = Partial stop Only with [Automatic
close] activated.
C4 = Obstacle standby (photocells)
C7 = Reopen while closing (sensitive
edges)
C8 = Reclose while opening (sensitive
edges)
Safety devices test
Check that the photocells connected to the inputs are operating correctly, after each opening and closing command.
The safety devices test function is always active for wireless safety devices.
F5 Safety devices test OFF (Default)
1 = CX
2 = CY
4 = CX+CY
Hold-to-run
With the function active, the operator stops moving (opening or closing) when the control device is released.
When the function is active, it excludes all other control devices.
F6 Hold-to-run OFF (Default)
ON

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Command 2-7
Associate a command with the device connected to 2-7.
F7 Command 2-7 0 = Step-by-step (default)
1 = Sequential
2 = Open
3 = Close
Command 2-3P
Associate a command to the connected device on 2-3P.
F8 Command 2-3P 0 = Pedestrian opening (Default)
Complete opening of M2 only.
1 = Partial opening
Partial opening of M2 only.
The M2 opening degree is set
as a percentage, with function [F36]
Partial opening adjustment.
2 = Open
Obstruction detection with motor idle
With the function active, the gate remains idle if the safety devices detect an obstacle. The function is active when the gate is
closed, open or after a complete stop.
F9 Obstruction detection with motor
idle
OFF (Default)
ON
Open warning light or enable electric lock
It signals the gate status or enables the electric lock. Device connected the 10-5 output.
F10 Open warning light or enable
electric lock
0 = Warning light on (default) - The
warning light stays on when the gate is
moving or open.
1 = Warning light flashing - The
warning light flashes every half second
when the gate is opening and stays
on when the gate is open. The light
flashes every second when the gate is
closing, and remains o when the gate
is closed.
2 = The output enables an electric lock.
Encoder
Manage operator slowdowns, obstacle detection and sensitivity.
F11 Encoder ON (Default)
OFF

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Soft start
Set a slowdown of a few seconds after each opening and closing command.
F12 Soft start OFF (Default)
ON
Closing thrust
When the leaves reach the closing limit-switch, the operator performs a closing thrust for a few seconds.
F13 Closing thrust OFF (Default)
1 = Minimum thrust
2 = Medium thrust
3 = Maximum thrust
Sensor type
Set the type of control device.
F14 Sensor type 0 = Transponder selector or magnetic
card reader
1 = Keypad selector (default)
Thrust
Before every opening or closing manoeuvre, the leaves thrust inwards to release the electric lock.
F16 Thrust OFF (Default)
ON
Additional light
Choose the operating mode of the lighting device connected to output 10-E.
F18 Additional light 0 =Flashing beacon (Default)
1 = Cycle light
The lamp stays on during the
manoeuvre.
Parameter [1] appears only if an
automatic closing time is set.
Automatic closure
Set the time before automatic closure is activated, once the opening travel end point has been reached or once the photocells
have caused a partial stop [C3].
The function does not work if any of the safety devices are triggered when an obstacle is detected, or after a
complete stop, or during a power outage.
F19 Automatic close OFF (Default)
From 1 to 180 seconds

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Automatic closing after either partial or pedestrian opening.
Set the time before automatic closure is activated, after a partial opening command has been performed or after the
photocells have caused a partial stop [C3].
The function does not work if any of the safety devices are triggered when an obstacle is detected, or after a
complete stop, or during a power outage.
F20 Automatic closing after either
partial or pedestrian opening.
OFF (Default)
From 1 to 180 seconds
Pre-flashing time
Set the time for which the beacon is activated before each manoeuvre.
F21 Pre-flashing time OFF (Default)
1 to 10 seconds
Operating time
Set the gearmotor working time during opening and closing.
F22 Operating time 5 to 180 seconds (Default 120)
M1 opening delay time
It adjusts the delay with which the first leaf must start the opening manoeuvre with respect to the second leaf.
F23 M1 opening delay time 0 to 10 seconds (Default 2)
M2 closing delay time
It adjusts the delay with which the second leaf must start the closing manoeuvre with respect to the first leaf.
F24 M2 closing delay time 0 to 25 seconds (Default 5)
Thrust time
Adjust the gearmotor closing thrust time after an opening or closing command.
F26 Thrust time 1 to 2 seconds (Default 1)
Electric lock time
Adjust the electric lock release time after an opening or closing command.
F27 Electric lock time 1 to 4 seconds (Default 1)
Gate travel speed
Set the travel speed (percentage of maximum speed).
F28 Gate travel speed 40% to 100% (Default 100%)
Slowdown speed
Set the slowdown speed (percentage of maximum speed).
F30 Slowdown speed 15% to 60% (Default 50%)