CAME ATI KIT User manual

ATI KIT
CAME UNITED KINGDOM LTD
ORCHARD PARK INDUSTRIAL ESTATE
TOWN STREET, SANDIACRE,
NOTTINGHAM, NG10 5BP
TEL: [phone]
FAX: [phone]
INTERNET - www.came k.com
E-MAIL - enq iries@came k.com
TECHNICAL
HELPLINE
0115 921 0430
Installation Instructions
for a “Pair” of gates...
THE ATI-P KIT CONSISTS OF:
2 X ATI MOTORS
1 X CONTROL PANEL
1 X RADIO FREQUENCY CARD
1 X TUNED ANTENNA
2 X REMOTE CONTROL TRANSMITTERS
1 X PAIR SAFETY BEAMS

THESE INSTRUCTIONS WILL SHOW YOU HOW TO INSTALL
AN ATI GATE KIT TO A PAIR OF GATES.
PLEASE READ THESE INSTRUCTIONS AND DIAGRAMS
CAREFULLY BEFORE STARTING ANY WORK.
1
UNDER NO CIRCUMSTANCES SHOULD THIS EQUIPMENT BE OPERATED UNLESS FITTED TO A GATE.
FAILURE TO COMPLY WILL INVALIDATE THE GUARANTEE.
INTRODUCTION

INSTALLATION INSTRUCTIONS
CONTENTS
1) Stage 1:- Civil & Mechanical Section Page
1.1 BASIC HINGE GEOMETRY 3
1.2 BASIC CABLE LAYOUT 4
1.3 LOW VOLTAGE CABLE LAYOUT 5
1.4 ATTACHING BRACKETS 5
1.5 ATTACHING THE REAR BRACKET 6
1.6 ATTACHING THE FRONT BRACKET
) Stage :- Wiring & Electrical
2.1 FITTING THE CONTROL PANEL IN THE CASING 9
2.2 GAINING ACCESS TO MOTORS 10
2.3 INSTALLING THE MOTORS 11
2.4 ADJUSTING OPEN/STOP LIMIT SWITCH 11
2.5 WIRING THE MOTORS 13
2.6 WIRING THE SAFETY PHOTOCELLS 14
2. INSERTING THE FREQUENCY CARD 14
2.8 WIRING IN THE TUNED ANTENNA 15
2.9 CODING THE REMOTE CONTROLS 15
2.10 POWERING UP THE CONTROL PANEL 15
3) Stage 3:- Commissioning the Control Panel
3.1 INITIAL WIRING & CONTROL PANEL SETUP 1
3.2 OPENING & CLOSING THE GATES 18
3.3 CONTROL PANEL ADJUSTMENTS 19
3.4 AUTOMATIC CLOSE & SAFETY PHOTOCELLS 20
3.5 PROGRAMMING THE REMOTE CONTROLS TO THE
CONTROL PANEL 21
4) Troubleshooting Guide 23
5) Technical Information
5.1 TECHNICAL SPECIFICATIONS 25
5.2 MOTOR TORQUE SETTINGS 26
5.3 ZA4 CONTROL PANEL DESCRIPTION 2
5.4 ZA4 WIRING DIAGRAM 29
5.5 CONTROL PANEL ADJUSTMENTS 30
5.6 ELECTRICAL CONNECTIONS 31
7) Contact Information
“TIME MARCHES ON BUT CAME AUTOMATION EQUIPMENT STANDS THE TEST OF TIME...”

3
STAGE 1
CIVIL & MECHANICAL SECTION
1.1- Basic Hinge Geometry
BEFORE BEGINNING YOUR INSTALLATION OF YOUR ATI SYSTEM, CHECK THE
FOLLOWING:
* YOUR GATE PIERS OR POSTS ARE SUFFICIENTLY STRONG ENOUGH
TO SUPPORT THE GATES AND OPERATORS AND THE GATES SWING
FREELY AND THERE IS NO FRICTION BETWEEN THE MOVING PARTS.
* MEASUREMENT C MUST NOT BE GREATER THAN THE VALUE SHOWN
BELOW. IF THIS IS THE CASE, IT IS NECESSARY TO MODIFY THE
PILLAR SO THAT THIS MEASUREMENT CORRESPONDS.
Fig 1
C
PILLAR PILLAR
C
CENTRE STOP
HINGE HINGE
* ENSURE THAT A GATE CENTRE STOP IS SECURELY CONCRETED INTO THE
GROUND AND AS A GUIDE, THE CENTRE STOP SHOULD NOT PROTRUDE OUT
OF THE GROUND NO MORE THAN 65mm, IF IT IS MUCH HIGHER IT MAY
CATCH ON THE UNDER-SIDE OF A CAR.
Dimension C must be no greater than 120mm for 90 opening and
no greater than 0mm for a 130 opening.

1. - Basic Cable Layout
THIS DIAGRAM DETAILS THE BASIC CABLE LAYOUT FOR
A PAIR OF MOTORS.
THE POWER SUPPLY TO THE CONTROL PANEL SHOULD BE LIVE AND
PROTECTED IN ACCORDANCE WITH THE 16TH EDITION ELECTRICAL
REGULATIONS. THE SUPPLY SHOULD BE RATED AT A MINIMUM OF 6 AMPS.
WHEN INSTALLING WIRES OUTDOORS THE CABLE APPROACH TO ALL
DEVICES MUST BE FROM BELOW TO CREATE A “DRIP-LOOP” AND THEREBY
AVOID UNNECCESSARY WATER INGRESS.
4
Fig 2
WHEN INSTALLING LOW VOLTAGE CABLE AROUND THE GATEWAY IT IS
ADVISED TO PUT ALL LOW VOLTAGE CABLE IN EITHER DUCTING OR
ALKATHENE PIPING. ALL CABLE JOINTING SHOULD BE CARRIED OUT
ABOVE GROUND.
CONTROL PANEL
HOUSING
40V A.C 3 CORE
1.5mm SWA
4 CORE
1.5mm FLEX JOINT BOX

5
1.3 - Low Voltage Cable Layout
ALL CAME ACCESSORIES CAN BE WIRED 0.2m STRANDED CABLE (BUGLAR
ALARM TYPE). THE TUNED ANTENNA SHOULD BE WIRED WITH COAXIAL
CABLE (RG59).
WELD THE 9 HOLE BRACKET TO THE FIXING PLATE THEN SECURLEY
ATTACH THE FIXING BRACKET TO THE PIER OR POST, OBSERVE
MEASUREMENT A AND B BETWEEN THE HINGE PIN AND THE CENTRAL
HOLE IN THE BRACKET.
1.4 - Attaching Brackets
Fig 3
TUNED
ANTENNA
COAXIAL
CABLE DOC E SAFETY
BEAMS
8 CORE 0. mm STRANDED
CABLE TO ALL SAFETY BEAMS
Fig 4
A
REAR BRACKET
FIXING PLATE
B
Opening AB
mm mm
90
130
00
00
00
140

6
THE REAR BRACKET IS EQUIPPED WITH ADDITIONAL HOLES TO MAKE
INSTALLATION OF THE GATE MOTOR EASIER, OR TO CHANGE THE
OPENING ANGLE OF THE GATE. THE REAR BRACKET CAN BE LENGHENED
OR SHORTENED TO SUIT THE INDIVIDUAL INSTALLATION SITE AND THE
POSITION OF THE GATES (WITH RESPECT TO THE PILLARS).
N.B IF MEASUREMENT B IS INCREASED, THE ANGLE OF APETURE IS
REDUCED. THIS THEREFORE REDUCES THE PERIPHERAL SPEED
AND INCREASES THE THRUST EXERTED BY THE MOTOR ON THE
GATE. IF MEASUREMENT A IS INCREASED, THE ANGLE OF
APERTURE IS INCREASED. THIS THEREFORE INCREASES THE
PERIPHERAL SPEED AND REDUCES THE THRUST EXERTED BY THE
MOTOR ON THE GATE.
WHEN THE REAR BRACKET IS SECURELY ATTACHED TO THE PIER OR POST,
INSERT THE BUSH INTO THE DESIRED HOLE AND ATTACH THE REAR JOINT
ARM, LUBRICATING WITH A NEUTRAL GREASE.
Fig 5
MB
REAR JOINT
M8 X 38
BUSHING
1.5 - Attaching the Rear Bracket

7
WITH THE GATE IN THE FULLY CLOSED POSITION WELD THE FRONT
BRACKET TO THE FIXING PLATE THEN ATTACH IT TO THE GATE. THE
ANCHOR PLATE MUST BE HORIZONTALLY ALIGNED WITH THE REAR
BRACKET MOUNTED ON THE PEIR OR POST ENSURING DIMENSION IS
OBSERVED.
N.B WHEN INSTALLING THE UNIT ON SPECIAL FRAMES, IT MAY BE
NECCESSARY TO FIT ADDITIONAL SPACERS WITH A MINIMUM
THICKNESS OF 10mm IN ORDER TO PREVENT CONTACT BETWEEN
THE OPERATOR AND THE GATE WING.
THICKNESS
MIN 10mm
FIXING
PLATE
LEVEL THE BRACKET
FRONT
BRACKET
E=880 mm
Fig 6
1.6 - Attaching the Front Bracket

BEFORE STARTING STAGE - Wiring & Electrical
PLEASE CHECK THAT YOU HAVE CORRECTLY:
Ref
Page
1. PREPARED THE CABLING CORRECTLY 1. 4
. CORRECTLY ATTACHED THE BRACKETS 1.4 5
NOW STAGE 1 IS FULLY COMPLETED YOU ARE READY TO
BEGIN STAGE OF YOUR ATI AUTOMATION KIT
INSTALLATION
END OF INSTALLATION
STAGE 1
8

9
STAGE - WIRING & ELECTRICAL
.1 - Fitting the Control Panel in the Casing
Securely fasten the control panel PCB to the
casing with the screws supplied.
Plug the green connector from the transformer to
the PCB ensuring that it connects the correct way.
NB FROG Series Motors: connect the black wires
coming out of the board to one capacitor and the
red wires to the other.
Screws
Screw positioning holes
Green connector point
Fastening screws

10
. - Gaining Access to the Motors
TO GAIN ACCESS TO THE MOTOR TERMINALS AND WORM DRIVE FIRST
REMOVE THE COVERS. FIRST REMOVE THE SCREWS FROM THE TOP
COVER. THEN REMOVE THE TWO SCREWS THAT SECURE THE WORM
DRIVE COVER.
Fig 7
Fig 8
CASING
COVER

WITH THE COVERS REMOVED INSTALL THE MOTOR ON THE TWO
BRACKETS AND SECURE THE MOTOR WITH THE NUTS AND BOLTS
PROVIDED.
Fig
M8 X 50 M8 X 10
WORM-GEAR
M8 LOCKNUT
.4 - Adjusting the Open Stop Microswitch
MANUALLY RELEASE THE REDUCTION GEAR BY INSERTING THE RELEASE
KEY AND TURNING IT 180.
180°
Fig 10
11
.3 - Installing the Motors

12
MOVE THE GATE TO THE DESIRED OPEN POSITION. LOOSEN THE SCREWS
WHICH HOLD THE MICROSWITCH IN POSITION. SLIDE THE MICROSWITCH
ON THE SUPPORT PLATE UNTIL THE MICROSWITCH IS TRIPPED. THEN
TIGHTEN THE SCREWS TO ANCHOR THE MICROSWITCH IN POSITION.
FIXING SCREW
SCREWNUT
WORM-
GEAR
SUPPORT PLATE
MICROSWITCH
MICROSWITCH
Fig 11

13
U V W X Y E E3
U V W W X Y
MOTOR 1 MOTOR 2
MOTOR
EARTH MOTOR EARTH
.5 - Wiring the Motors
ENSURE BOTH MOTORS ARE ADEQUATELY EARTHED.
Fig 12

ZA4
.6 - Wiring in the Safety Photocells
SAFETY BEAMS SHOULD BE FITTED APPROXIMATELY
15 INCHES FROM GROUND LEVEL
CONTROL PANEL
10 11 2 C1
C
NC
RX
10
11
TX
10
11
Fig 13
SAFETY
BEAM
RECEIVER
SAFETY
BEAM
TRANSMITTER
IF FITTING A SECOND ARC LINE SET OF SAFETY BEAMS THEN C & NC MUST BE WIRED IN “SERIES”
.7 - Inserting the Radio Frequency Card
INSERT THE RADIO FREQUENCY
CARD INTO THE SMALL SOCKET
ON THE CONTROL PANEL
(ENSURE THAT THE POWER IS
TURNED OFF TO THE CONTROL
PANEL BEFORE INSERTING THE
FREQUENCY CARD)
ANTENNA
WIRING
POINT
Fig 14
NC
C
14

.8 - Wiring in the Tuned Antenna
.9 - Coding the Remote Controls
1. REMOVE THE BATTERY COVER & CASING OF THE REMOTE CONTROL
HANDSET TO REVEAL THE DIAGRAM BELOW
.10 - Powering up the Control Panel
CONNECT PROTECTED MAINS POWER TO TERMINALS L1 + L2 IN THE
CONTROL PANEL (L BEING LIVE!). ENSURE THAT THE CONTROL PANEL
IS ADEQUATELY EARTHED.
ANTENNA
WIRING
POINT
Fig 15
Bat
Battery 12V
ON 1 2 3 4 5 6 7 8 9 10
8 9 10
ON OFF
Bt
Batt
1
2. SET THE BANK OF
DIPSWITCHES ON
ALL REMOTES TO
EXACTLY THE SAME
CODE OF YOUR
CHOICE.
3. UNLESS PROGRAMMING FOR GATES AND
GARAGE DOORS TO OPEN BY REMOTE
CONTROL FROM THE SAME HANDSET ENSURE
THAT THE JUMPER STRAPS SHOWN HERE ARE
IN THE SAME POSITIONS ON ALL REMOTES
Fig 16
15

END OF INSTALLATION
STAGE
BEFORE STARTING STAGE 3 -
Commissioning the Control Panel
PLEASE CHECK THAT YOU HAVE CORRECTLY:
Ref Page
1. GAINED ACCESS TO MOTORS .1 9
. INSTALLED MOTORS . 10
3. ADJUSTED OPEN/STOP LIMIT SWITCH .3 10
4. WIRED THE MOTORS .4 1
5. WIRED THE SAFETY PHOTOCELLS .5 13
6. INSERTING THE FREQUENCY CARD .6 13
7. WIRED THE TUNED ANTENNA .7 14
8. CODED THE REMOTE CONTROLS .8 14
9. POWERED UP THE CONTROL PANEL .9 14
NOW STAGE IS FULLY COMPLETED YOU ARE READY TO
BEGIN STAGE 3 OF YOUR ATI AUTOMATION KIT
INSTALLATION
16

STAGE 3
COMMISSIONING THE CONTROL PANEL
3.1 - Initial Wiring & Control Panel Setup
1. CONNECT POWER TERMINALS L1 - L2
AND A SUITABLE EARTH (L BEING LIVE!)
2. SELECT THE MOTOR POWER SETTING ON
THE TRANSFORMER TO LEVEL 1 FOR
COMMISSIONING
Fig 17
3. SELECT DIPSWITCHES 1 & 2 OFF FOR
COMMISSIONING
4. ENSURE HARD WIRE LINK IS FITTED
BETWEEN TERMINALS 1 & 2 AND
2 & C1
ON
OFF
1 2 3 4 5 6 7 8 9 10
Fig 18
Fig 1
10 11 S 1 2 3 3P 4 5 7 2 C1 CX B1 B2
17

3. - Opening & Closing the Gates
2. ONCE YOU HAVE PROVED THE
MOTOR DIRECTION USE
TERMINALS 2 & TO OPEN AND
CLOSE THE GATES WITH A
TRAILING WIRE ONCE AGAIN INTO
TERMINAL 2, MOMENTARILY
TOUCHING TERMINAL .
18
1. MOMENTARILY PULSE TERMINALS
2 & 3 WITH A PIECE OF WIRE
TRAILING FROM TERMINAL 2 AND
MOMENTARILY TOUCHING
TERMINAL 3.
THE GATES SHOULD START TO
OPEN. IF THEY START TO CLOSE
TURN THE POWER OFF TO THE
CONTROL PANEL AND CHANGE
AROUND EITHER U-V (MOTOR 1)
OR X-Y (MOTOR 2) TO CHANGE
THE MOTOR DIRECTION.
Fig 20
Fig 21
L1 L2 U V W X Y E1 10 11 1 2 3 5 7 C1
L1 L2 U V W X Y E1 10 11 1 2 3 5 7 C1

TRIMMER TR2M
3.3 - Control Panel Adjustments
TRIMMER TL
1. TO DELAY ONE GATE LEAF, ADJUST POTENIOMETER TR2M TO DELAY
THE CLOSING OF GATE NO. 2 IN THE CLOSING CYCLE
2. TO SET THE TOTAL RUNNING TIME OF THE MOTORS, ADJUST
POTENIOMETER TL TO ALLOW THE MOTORS TO RUN FOR A FURTHER
5- SECONDS AFTER THE MOVEMENT CYCLE HAS BEEN COMPLETED
(I.E FULLY OPEN OR FULLY CLOSED)
3. CHECK THE SENSITIVITY OF THE GATES
BY TRYING TO PHYSICALLY STOP THE
GATE AND ADJUST THE POWER
SETTINGS ON THE TRANSFORMER
ACCORDINGLY. IF MORE POWER IS
NEEDED FOR HEAVIER GATES THEN
SWITCH OFF POWER AND MOVE
TRANSFORMER WIRE UP TO SETTING 2.
FOR RECHECKING SENSITIVITY, REPEAT
PROCESS UP TO 3 OR 4 IF EVEN MORE
POWER IS NEEDED.
Fig 22
Fig 23
Fig 24
19