CAME Ferni Series User manual

F ERNI K I T
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 “Single” gate...
THE FERNI-S KIT CONSISTS OF:
1 X FERNI MOTOR
1 X CONTROL PANEL
1 X RADIO FREQUENCY CARD
1 X TUNED ANTENNA
2 X REMOTE CONTROL TRANSMITTERS
1 X PAIR SAFETY PHOTOCELLS

THESE INSTRUCTIONS WILL SHOW YOU HOW TO INSTALL
A FERNI MOTOR TO A SINGLE GATE.
PLEASE READ THESE INSTRUCTIONS AND DIAGRAMS
CAREFULLY BEFORE STARTING ANY WORK.
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 PRE-INSTALLTION CHECK 3
1.2 MOUNTING THE MOTOR BASE PLATE 4
) Stage :- Wiring & Electrical
2.1 FITTING THE CONTROL PANEL IN THE CASING 6
2.2 BASIC CABLE LAYOUT 7
2.3 LOW OLTAGE CABLE LAYOUT 8
3) Stage 3:- Installation Section
3.1 INSTALLING THE MOTORS 10
3.2 INSTALLING THE DRI E ARMS 11
3.3 ADJUSTING THE OPEN & CLOSED CAMS 12
4) Stage 4:- Wiring & Electrical ( )
4.1 WIRING THE MOTORS 14
4.2 WIRING THE SAFETY PHOTOCELLS 15
4.3 INSERTING THE FREQUENCY CARD 15
4.4 WIRING IN THE TUNED ANTENNA 16
4.5 CODING THE REMOTE CONTROLS 16
4.6 POWERING UP THE CONTROL PANEL 16
5) Stage 5:- Commissioning the control Panel
5.1 INITIAL WIRING & CONTROL PANEL SETUP 18
5.2 OPENING & CLOSING THE GATES 19
5.3 CONTROL PANEL ADJUSTMENTS 20
5.4 AUTOMATIC CLOSE & SAFETY PHOTOCELLS 21
5.5 PROGRAMMING THE REMOTE CONTROLS TO THE
CONTROL PANEL 22
5.6 FINAL ASSEMBLEY 23
6) Troubleshooting Guide 25
7) Technical Information
7.1 TECHNICAL SPECIFICATIONS 27
7.2 MOTOR TORQUE SETTINGS 28
7.3 ZA5 CONTROL PANEL DESCRIPTION 29
7.4 ZA5 WIRING DIAGRAM 31
7.5 CONTROL PANEL ADJUSTMENTS 32
7.6 ELECTRICAL CONNECTIONS 33
8) Contact Information

3
STAGE 1
CIVIL & MECHANICAL SECTION
1.1 - Pre-Installation Check
BEFORE BEGINNING YOUR FERNI S GATE INSTALLATION CHECK THE
FOLLOWING:
THE GATE POST OR PIERS ARE STRONG ENOUGH TO SUPPORT THE GATE
AND THE MOTOR
THE GATE IS STRONG ENOUGH TO BE AUTOMATED.
THE GATE SWINGS FREELY FROM OPEN TO CLOSE AND THERE IS NO
FRICTION ON THE HINGS.
Fig 1
IF DISTANCE B IS 0 TO 300mm: DISTANCE A MUST BE AT LEAST 110mm.
IF DISTANCE B IS 300mm TO 380mm: DISTANCE A MUST BE AT LEAST
150mm.

4
1. - Mounting the Motor Base Plate
USING SUITABLE ANCHOR BOLTS OR CHEMICAL RESIN FOR BRICK PIER
SECURITY MOUNT THE MOTOR PLATE TO THE BRICK PIER.
FOR WOODEN POSTS IT IS AD ISED TO FIX THE MOTOR PLATE TO THE
POST. A THREADED BAR SHOULD BE PLACED ALL THE WAY THROUGH THE
POST THEN BOLTED. Fig 3
Fig 2
WHEN MOUNTING THE MOTOR PLATE BE SURE TO RESPECT THE 150mm
DIMENSION FROM THE BOTTOM OF THE MOTOR PLATE TO GROUND LE EL.
THIS IS TO ENSURE SUFFICIENT CLEARENCE FOR THE TRANSMISSION
DRI E ARM TO BE INSERTED THROUGH THE MOTOR.
ENSURE THAT THE DISTANCE BETWEEN THE CENTRE OF THE FRONT
BRACKET ‘A’ 450mm. THE FRONT GATE BRACKET MUST BE FIXED LOWER
THAN THE MOTOR PLATE BY 19mm AS SHOWN
150 mm 19mm
Fig 4
Bracket “A”
Base Plate

5
BEFORE STARTING STAGE - Wiring & Electrical
PLEASE CHECK THAT YOU HAVE CORRECTLY:
Ref Page
1. Checked Requirements 1.1 3
. Mounted Motor Base Plate 1. 4
NOW STAGE 1 IS FULLY COMPLETED YOU ARE READY TO
BEGIN STAGE OF YOUR FERNI AUTOMATION KIT
INSTALLATION
END OF INSTALLATION
STAGE 1

6
STAGE - WIRING & ELECTRICAL
.1 - Fitting the Control Panel in the Casing
Screws
Screw positioning holes
Green connector point
Fastening screws
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.

7
. - Basic Cable Layout
Fig 5
THIS DIAGRAM DETAILS THE BASIC CABLE LAYOUT FOR
A SINGLE MOTOR.
THE POWER SUPPLY TO THE CONTROL PANEL SHOULD BE LI E 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
DE ICES MUST BE FROM BELOW TO CREATE A “DRIP-LOOP” AND THEREBY
A OID UNNECCESSARY WATER INGRESS.
WHEN INSTALLING LOW OLTAGE CABLE AROUND THE GATEWAY IT IS
AD ISED TO PUT ALL LOW OLTAGE CABLE IN EITHER DUCTING OR
ALKATHENE PIPING. ALL CABLE JOINTING SHOULD BE CARRIED OUT
ABO E GROUND.
Joint Box
3 Core 1.5mm SWA
Control Panel
4 Core Flex

8
.3 - Low Voltage Cable Layout
Fig 6
ALL CAME ACCESSORIES CAN BE WIRED 0.2m STRANDED CABLE (BUGLAR
ALARM TYPE). THE TUNED ANTENNA SHOULD BE WIRED WITH COAXIAL
CABLE (RG59).
Joint Box
Low oltage
4 Core Flex
Control Panel
Safety Photocells
Tuned Antenna
Coaxial Cable
3 Core SWA 1.5m

BEFORE STARTING STAGE 3 - Installation
PLEASE CHECK THAT YOU HAVE CORRECTLY:
Ref Page
1. Fitted the Control Panel in the Casing .1 6
. Installed Basic Cable Layout . 7
. Installed Low Voltage Cable Layout .3 8
NOW STAGE IS FULLY COMPLETED YOU ARE READY TO
BEGIN STAGE 3 OF YOUR FERNI AUTOMATION KIT
INSTALLATION
END OF INSTALLATION
STAGE
9

10
STAGE 3
INSTALATION SECTION
3.1 - Installing the Motor
INSERT THE MOTOR INTO THE MOTOR BASE PLATE IN ALIGNMENT WITH
THE 4 PRE-DRILLED HOLES AND FIX IT WITH THE TWO M8 X 110 BOLTS &
NUTS SUPPLIED. FOR RIGHT HAND INSTALLATIONS, RE ERSE THE
POSITION OF THE MOTOR AND USE THE SECOND PAIR OF HOLES
(SEE FIGURE 7)
Fig 7

3. - Installing the Drive Arms
INSERT THE STRAIGHT ARM THROUGH THE GEARBOX, HOLDING IT IN
PLACE FIT THE FLARED WASHER USING THE M6 X 20 COUNTER SUNET
SCREW. GRIP THE SHAFT IN PLACE BY TIGHTENING THE FOUR GRUB
SCREWS TOP AND BOTTOM OF THE GEARBOX. JOIN AND FIX THE TWO
ARMS TOGETHER WITH THE WASHER AND THE M8 X 16 BOLT.
FIT THE CUR ED ARM TO THE FRONT MOUNTING BRACKET USING THE
M12 X 50 BOLT AND M12 NUT.
RELEASE THE MOTOR (ROTATING THE HAND GRIP IN THE DIRECTION OF
THE ARROW.
Fig 8
Fig
M6 x 20
Countersink Washer
Knob
M12 x 50
M8 x 16
11

3.3 - Adjusting the Open & Closed Cams
OPEN POSITION
RELEASE THE GATE MOTOR AND MO E THE GATE TO THE DESIRED OPEN
POSITION. NOW ROTATE THE UPPER CAM UNTIL IT MAKES CONTACT WITH
THE MICROSWITCH. CLOSE THE GATE AND TIGHTEN THE SCREW IN THE
CAM.
CLOSED POSITION
RELEASE THE GATE MOTOR AND MO E THE GATE TO THE DESIRED
CLOSED POSITION. NOW ROTATE THE LOWER CAM UNTIL IT MAKES
CONTACT WITH THE MICROSWITCH. OPEN THE GATE AND TIGHTEN THE
SCREW IN THE CAM.
Fig 10
12
LOWER CAM
MICROSWITCH
UPPER CAM

13
BEFORE STARTING STAGE 4 - Wiring & Electrical ( )
PLEASE CHECK THAT YOU HAVE CORRECTLY:
Ref Page
1. Installed the Motor 3.1 9
. Installed the Drive Arm 3. 10
3. Adjusted the Open & Closed Cams 3.3 11
NOW STAGE 3 IS FULLY COMPLETED YOU ARE READY TO
BEGIN STAGE 4 OF YOUR FERNI AUTOMATION KIT
INSTALLATION
END OF INSTALLATION
STAGE 3

14
STAGE 4
WIRING & ELECTRICAL ( )
4.1 - Wiring the Motor
ENSURE THAT THE MOTOR IS ADEQUATELY EARTHED.
Fig 11
U V W
MOTOR
EARTH
L1 L2 U V W E1 ES 10 11 1 2 3 5 7 C1

4. - Wiring in the Safety Photocells
SAFETY BEAMS SHOULD BE FITTED APPROXIMATELY
15 INCHES FROM GROUND LE EL
Fig 12
SAFETY
BEAM
RECEI ER
SAFETY
BEAM
TRANSMITTER
IF FITTING A SECOND ARC LINE OF SAFETY BEAMS THEN C & NC MUST BE WIRED IN “SERIES”
4.3 - 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 13
NC
C
15
ZA4

16
4.4 - Wiring in the Tuned Antenna
4.5 - Coding the Remote Controls
1. REMO E THE BATTERY CO ER & CASING OF THE REMOTE CONTROL
HANDSET TO RE EAL THE DIAGRAM BELOW
4.6 - 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 14
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 15

END OF INSTALLATION
STAGE 4
BEFORE STARTING STAGE 5 - Commissioning the
Control Panel
PLEASE CHECK THAT YOU HAVE CORRECTLY:
Ref Page
1. WIRED THE MOTOR AS SHOWN 4.1 13
. WIRED IN THE SAFETY PHOTOCELLS 4. 14
3. INSERTED THE RADIO FREQUENCY
CARD 4.3 14
4. WIRED IN THE TUNED ANTENNA 4.4 15
5. PROGRAMMED THE REMOTE CONTROLS 4.5 15
6. POWERED UP THE CONTROL PANEL 4.6 15
NOW STAGE 4 IS FULLY COMPLETED YOU ARE READY TO
BEGIN STAGE 5 OF YOUR FERNI AUTOMATION KIT
INSTALLATION
17

18
STAGE 5
COMMISSIONING THE CONTROL PANEL
5.1 - 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 LE EL 1 FOR
COMMISSIONING
Fig 16
Fig 17
Fig 18
3. SELECT DIPSWITCHES 1 & 2 OFF FOR
COMMISSIONING
4. ENSURE HARD WIRE LINK IS FITTED
BETWEEN TERMINALS 1 & 2 AND
2 & C1
L1 L2 U V W E1 ES 10 11 1 2 3 5 7 C1

5. - Opening & Closing the Gate
2. ONCE YOU HA E PRO ED THE
MOTOR DIRECTION USE
TERMINALS 2 & 7 TO OPEN AND
CLOSE THE GATES WITH A
TRAILING WIRE ONCE AGAIN INTO
TERMINAL 2, MOMENTARILY
TOUCHING TERMINAL 7.
1. MOMENTARILY PULSE TERMINALS
2 & 3 WITH A PIECE OF WIRE
TRAILING FROM TERMINAL 2 AND
MOMENTARILY TOUCHING
TERMINAL 3.
THE GATE SHOULD START TO
OPEN. IF THE MOTOR STARTS TO
CLOSE TURN THE POWER OFF TO
THE CONTROL PANEL AND CHANGE
AROUND X-Y (MOTOR 2) TO
CHANGE THE MOTOR DIRECTION.
Fig 1
Fig 20
19
L1 L2 U V W E1 ES 10 11 1 2 3 5 7 C1
L1 L2 U V W E1 ES 10 11 1 2 3 5 7 C1