CAME ZL38 User manual

ZL38
AUTOMAZIONE PER CHIUSURA INDUSTRIALE
INSTALLATION MANUAL
COMMAND BOARD FOR BARRIERS
WITH 24V MOTOR
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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.
Thecommand boardis powered at 230V A.C.onthe L-Nterminalswith 50÷60 Hz frequencyand isprotected in inputwith 3.15A
fuses.
A 2A fuse protects the low-voltage (24V) command devices.
630mA control unit fuse. 10A motor fuse.
The overall rated power of the 24V accessories must not exceed 40 W.
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 obstacles (amperometric device)
that:
during opening: the bar stops;
during closing: the bar reverses its direction until it opens completely; automatic closure is thus activated.
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;
- Slave operations: in the case of two barriers working in pairs;
4 Description
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 24V 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
“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”

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: 400 W
Absorption at rest: 25W
Maximum power for 24V accessories: 20 W
Maximum power for 230V accessories: 200 W
Insulation type: II
Material case: ABS
Working temperature:
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4.2 Technical information
4.3 Main components
1 - 2A accessory fuse
2 - 3.15A line fuse
3 - 630 mA central unit fuse
4 - 10 A motor fuse
5 - Connecting terminal boards
6 - Radiofrequency board coupling (see table)
7 - SENS Trimmer: amperometric sensitivity adjustment
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6
5
4
9
Brown
Brown
Black
Brown
White
Red
Blue
Orange
White Red Black
- Function that increases the braking action of the barrier;
- Type of command: open-close or opening only
Settings: automatic closure time adjustment, amperometric sensitivity.
Optionalaccessories:
- flashing dome and lighted cord;
- bar open light marks the opening position of the bar; it turns off after the closing operation;
- LB38 card makes it possible to power the barrier using batteries in the event of mains power outage. When the mains power
comes back on, it also recharges the batteries (see the technical manual).
ATTENTION: before intervening inside the device, cut off the mains voltage and disconnect the batteries (if present).
8 - TCA Trimmer: automatic closure time adjustment
9 - “Function selection” dip-switch
10- Code saving button
11- Flashing radio code / automatic closing LED indicator
12- Transformer power connectors
13- Battery charger (LB35) connectors
14- Command-type selection jumper for pushbutton in 2-7

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.
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.
5.3 Cable list and minimun thickness
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
24V motors 2 x 1mm² 2 x 1,5mm² 2 x 2,5mm²
230V flashing lamp 2 x 0,5mm² 2 x 1mm² 2 x 1,5mm²
24V flashing lamp 2 x 0,5mm² 2 x 1mm² 2 x 1,5mm²
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. 50 m
Encoder connection 2402C 22AWG shielded cable max. 30 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
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5.4 Installing the electrical card
1) Unscrew the four
mounting screws (or three
in the case of the G4040) 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.
ZL 38
ZL38
1
2
G2080
G2080I G4040 G4040I
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Brown
Brown
White Red Black
3) Connect the terminal
boards of the transformer
housed in the container to the
command board.
White
Blue
Orange
Red
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
5.5 Electrical connections
10
E
L
N
+10
-11
1
2
2
3
M
N
2
C1
10
5
F
FA
2
C5
F
FC
2
7
M
230V (a.c.) power supply
24V(d.c.) motor
24V max. 32W output
Power supply to accessories 24V max. 30W
Stop button (N.C.)
Open button (N.O.)
Button for command
Contact (N.C.)
of «reopening during closing»
“Barrier open” pilot lamp (24V-3W max)
Contact (N.C.) of «immediate closing»
Microswitch connection slowdown during opening
Microswitch connection slowdown during closing
Antenna connection
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DIP 3 OFF - Flashing movement-indicating lamp
(e.g.: flashing dome lamp, luminous cord)
DIP 3 ON - Flashing movement-indicating lamp and
“Closed barrier” signalling lamp
N.B. Maintain polarity when connecting photoelectric cells (DIR)
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IF NOT USED
- operations of opening only or opening-closing
(see dip no. 2)
- operations of opening only (mandatory in the
case of “maintained action operations”
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IF NOT USED
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ON
OFF
- SENS. Trimmer = Amperometric device sensitivity (min. / max.)
- TCA Trimmer = Automatic closing time min 1 sec. - max. 120 sec.
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5.7 Adjustments
5.6 Function selections
1 ON Automatic Closing function activated; (1 OFF-deactivated);
2 ON “Open Only” function with pushbutton (2-7) and remote control (AF - board inserted) activated;
2 OFF “Open-Close-Reverse” Function with pushbutton (2-7) and remote control (HF board inserted) activated;
3 ON 24V (10-E) output activated when moving and when closed;
3 OFF 24V (10-E) output activated when moving;
4 ON “Steady action” function (remote control function disabled) activated;
5 ON Pre-flashing activated during opening and closing;
6 ON Obstacle presence detection activated; (6 OFF deactivated);
7 ON “Slave” (motor-driven) function activated;(7 OFF deactivated)
8 OFF Immediate bar closing function activated; insert safety device to terminals 2-C5 (8 ON deactivated).
9 OFF “Total Stop” function (connect the pushbutton on 1-2) activated; (if not used select ON dipswitch);
10 ON Increased barrier braking action function activated;(10 OFF deactivated)
5.8 Adjustment of the speed of movement and delays
To regulate the speed of opening and closing, move the fast-on of the
transformer indicated with “A” on Min = minimum, Med. = Medium or
Max. = maximum, while for slowdowns, move the fast-on “B” to minimum
or maximum.
E.g.: max. speed of opening and closing – max. slowdown (see drawing
on the right/left).
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All the data and information contained herein is considered subject to change at any time and at our discretion
ENGLISH
CAME
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5.9 Connection of two pairs of barriers with a single command
CAME
R
SX
DX
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MASTER
COMMAND BOARD
SLAVE
COMMAND BOARD
1) Designate the Master barrier (or pilot, namely the motor
that commands both barriers) and the Slave (motor piloted
by the Master).
2) On the command board designated
as the Master, execute all the wiring
connections (see page 6), the instal-
lation procedure for remote control,
settings and regulations.
On the command board designated as
the Slave, position the dip 7 to ON;
make the connections to the power
supply on the L-N terminal, con-
nect the device to the output
of the 10-E terminal, adjust
the speed of motion and
the slowdowns of the
Master barrier.
3) Execute the connection between the two command boards using the RX-TX-GND terminals.
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COMMAND BOARD
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Black Red Screened cable
2402C 22AWG

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All the data and information contained herein is considered subject to change at any time and at our discretion
ENGLISH
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).
2) The AF board should ALWAYS be inserted when
the power is off.
MOTHER BOARD
"AF" BOARD
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.
6.1 Prepare the radio board (AF)
6 Installation procedure of the transmitter for remote control
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 QUARZATI SERIES
6.2 Procedure for codifying the transmitter
TOP TAM
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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
Frequency/MHz Radiofrequecy 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

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
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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
TOP SERIES
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   
0 0
               
/. /. /. /.
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/. /. /. /.
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
ATOMO SERIES
CAME
TCH 4024 - TCH 4048
see instructions on pack
TOUCH SERIES

12
All the data and information contained herein is considered subject to change at any time and at our discretion
ENGLISH
6.3 Memorizing the code on the command board
1) Keep the "PROG" key pressed on the base card, the
signal LED will flash.
2) Press a transmitter key to send the code; the LED
will remain lighted to signal memorization.
N.B.: if the code needs to be changed, repeat the
sequence described above.
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Flashing LED
Lit LED
Radio board
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.
1
2
ZL38
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2
1
3
G2080
G2080I G4040 G4040I

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
8 Manufacturer’s warranty
MANUFACTURER’S DECLARATION
As per Enclosure II B of Machinery Directive 98/37/CE
Enclosed with the technical documentation (the original copy of the Declaration is available on request) Date of the present declaration 07/12/2001
The representatives of
CAME Cancelli Automatici S.p.A.
via Martiri della Libertà, 15
31030Dosson di Casier - Treviso - ITALYtel
([phone] - fax [phone]
internet: www.came.it - e-mail: [email protected]
Hereby declare, under their own respons ibility, that the product/s called ...
… comply with the Italian National Legal Provisions that transpose the
following Community Directives (where specifically applicable):
MACHINERY DIRECTIVE 98/37/CE
LOW VOLTAGE DIRECTIVE 73/23/EEC - 93/68/EEC
LECTROMAGNETIC COMPATIBILITY DIRECTIVE 89/336/EEC - 92/31/EEC
R&TTE DIRECTIVE 1999/5/CE
Also, they furthermore represent and warrant that the product/s that are the subject of the present
Declaration are manufactured in the respect of the following main harmonized provisions:
EN 292 PART 1 AND 2 MACHINERY SAFETY.
EN 12453 INDUSTRIAL, COMMERCIAL AND OTHER CLOSING MECHANISMS.
EN 12445 INDUSTRIAL, COMMERCIAL AND OTHER CLOSING MECHANISMS.
EN 12978 SAFETY DEVICES FOR POWER OPERATED DOORS AND GATES ....
EN 60335 - 1 SAFETY IN APPARATUSES FOR HOME USE.
EN 60204 - 1 MACHINERY SAFETY.
EN 61000 - 6 - 2 ELECTROMAGNETIC COMPATIBILITY.
EN 61000 - 4 - 4 ELECTROMAGNETIC COMPATIBILITY.
EN 61000 - 4 - 5 ELECTROMAGNETIC COMPATIBILITY.
IMPORTANT CAUTION!
It is forbidden to market/use product/s that are the subject of this declaration before completing and/or
incorporating them in total compliance with the provisions of Machinery Directive 98/37/CE
Signatures of the Representatives
TECHNICAL MANAGER
Mr. Gianni Michielan MANAGING DIRECTOR Mr. Paolo Menuzzo
ZL38