CAME FROG series User manual

FROG 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 “Single” gate...
THE FROG-S KIT CONSISTS OF:
1 X UNDERGROUND FOUNDATION CASINGS
1 X UNDERGROUND GATE MOTORS
1 X CONTROL PANEL
1 X RADIO FREQUENCY CARD
1 X TUNED ANTENNA
2 X REMOTE CONTROL TRANSMITTERS
1 X PAIR SAFETY BEAMS
0115 921 0430

THESE INSTRUCTIONS WILL SHOW YOU HOW TO INSTALL
A FROG UNDERGROUND GATE KIT 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 INSTALLATION OF THE FOUNDATION 3
1.2 BASIC CABLE LAYOUT 4
1.3 LOW VOLTAGE CABLE LAYOUT 4
1.4 INSTALLING THE MOTOR 5
1.5 HANGING THE GATE 5
1.6 FITTING THE GATE LOCK 6
) Stage :- Wiring & Electrical
2.1 FITTING THE CONTROL PANEL IN THE CASING
2.2 WIRING THE MOTOR 9
2.3 WIRING IN THE SAFETY PHOTOCELLS 10
2.4 INSERTING THE RADIO FREQUENCY CARD 10
2.5 WIRING IN THE TUNED ANTENNA 11
2.6 CODING THE REMOTE CONTROLS 11
2.7 POWERING UP THE CONTROL PANEL 11
3) Stage 3:- Commissioning the Control Panel
3.1 INITIAL WIRING & CONTROL PANEL SETUP 13
3.2 OPENING & CLOSING THE GATE 14
3.3 CONTROL PANEL ADJUSTMENTS 15
3.4 AUTOMATIC CLOSE & SAFETY PHOTOCELLS 16
3.5 PROGRAMMING THE REMOTE CONTROLS TO THE
CONTROL PANEL 17
4) Troubleshooting Guide 19
5) Technical Information 20
5.1 TECHNICAL SPECIFICATIONS 21
5.2 CASING DIMENSIONS 21
5.3 OPERATING LIMITS 21
5.4 MOTOR TORQUE SETTINGS 22
5.5 ZA5 CONTROL PANEL DESCRIPTION 23
5.6 ZA5 WIRING DIAGRAM 25
5.7 CONTROL PANEL ADJUSTMENTS 26
5. ELECTRICAL CONNECTIONS 27
5.9 DIPSWITCH FUNCTIONS 29
5.10 RE-HANDING THE MOTOR 30
6) Contact Information
“TIME MARCHES ON BUT CAME AUTOMATION EQUIPMENT STANDS THE TEST OF TIME...”

67mm
3mm
160mm
100mm 60mm
DUCTINGFOR
MOTORWIRES
HEEL OF CASINGSOAK AWAY
3
STAGE 1
CIVIL & MECHANICAL SECTION
1.1 - Installation of Foundation Casing
THE UNDERGROUND CASING SHOULD BE CONCRETED IN THE GROUND. THE
CASING SHOULD HAVE ADEQUATE DRAINAGE TO A SUITABLE SOAK AWAY.
WHEN INSTALLING THE FOUNDATION CASING AS A GUIDE ALLOW APPROXI-
MATELY 100mm AROUND THE CASING AND 100MM UNDERNEATH THE CASTING
FOR CONCRETE.
Fig 1
WHEN SETTING THE CASING IN PLACE ENSURE THAT THE TOP HINGE PIN IS PLUMB IN
LINE WITH THE HINGE PIVOT IN THE CASING. THE CENTRE OF PIVOT IS 65mm
STANDOFF FROM THE BACK OF THE CASING. THE CASING SHOULD BE SET PERFECTLY
SQUARE AND LEVEL AND PROTRUDING APPROXIMATELY 3MM FROM GROUND LEVEL.
WHEN CONCRETING THE CASING IN PLACE, ENSURE THAT THE HEEL OF THE CASING
IS PACKED WITH CONCRETE AS THIS WHERE ALL OF THE WEIGHT OF THE GATE WILL
SIT. ALLOW AT LEAST TWO DAYS FOR THE CONCRETE TO GO OFF.
Fig 2
67mm
3mm
160mm
100mm 60mm

1. - Basic Cable Layout
THIS DIAGRAM DETAILS THE BASIC CABLE LAYOUT FOR
A SINGLE MOTOR.
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
1.3 - Low Voltage Cable Layout
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.
ALL CAME ACCESSORIES CAN BE WIRED IN 0.2mm STRANDED LOW VOLTAGE CABLE
(BURGLAR ALARM TYPE). TUNED ANTENNA SHOULD BE WIRED WITH COAXIAL CABLE.
CONTROL
HOUSING
PANEL JOINT BOX
240V A.C.
3 CORE
SWA 1.5mm
MOTOR CABLE IN DUCTING
Fig 3
TUNED ANTENNA
CONTROL PANEL
HOUSING
COAX CABLE
DOC E SAFETY
BEAMS
8mm CORE 0.2mm
STRANDED TO ALL
SAFETY BEAMS
Fig 4

90°
5
1.4 - Installing the Motors
INSERT THE MOTORS ONTO THE STUDS IN THE CASING. IF THE GATES
ARE HUNG BETWEEN THE POSTS AND THE GATES OPEN INWARDS THE
MOTORS NEED TO BE POINTING INTO THE PROPERTY.
BEFORE ATTACHING THE GATE ENSURE THAT THE GATE PIVOT POINT IS
ADEQUATELY GREASED.
WHEN HANGING THE GATE ENSURE THAT IT IS SQUARE AND LEVEL
BEFORE WELDING THE GATE TO THE FROG SHOE. WHEN WELDING THE
GATE TO THE FROG SHOE DO NOT WELD OVER THE THREADED HOLES IN
THE SHOE.
WHEN HANGING A WOODEN GATE IT IS NECCESSARY TO CREATE A
U-SHAPED CARRYING SHOE IN MILD STEEL WHICH CAN BE WELDED TO
THE TOP SURFACE OF THE FROG SHOE. THEN THE WOODEN GATE CAN BE
BOLTED INTO POSITION WITH THE U-SHAPED CARRYING SHOE
CLAMPING TO THE BOTTOM OF THE GATE.
1.5 - Hanging the Gate
IF THE GATES ARE HUNG ON THE BACK OF THE POSTS THE MOTORS NEED
TO BE POINTING TOWARDS THE OTHER POST.
Fig 5
90°
MOTOR STOP
ADJUSTERS
BACKSTOP
A BACKSTOP AND
GATE CLOSING
STOPS ARE ALWAYS
ADVISED
CLOSING
STOP

6
1.6 - Fitting the Gate Lock
Secure the unlocking device to the FROG shoe with the 4 allen bolts provided.
To release the gate, raise the protective cap, insert the three sided key and turn it to activate the
mechanism. Simultaneously push and/or pull the gate. Remove the key and replace the protective cap.
To re-engage the gate, reposition the gate and the mechanism will automatically engage it.
Fig.
1
Fig.
2
Unloc
king
c
king
c
Fig.
3

7
BEFORE STARTING STAGE - Wiring & Electrical
PLEASE CHECK THAT YOU HAVE CORRECTLY:
Ref Page
1. INSTALLED THE FOUNDATION CASING 1.1 3
. PREPARED THE CABLING CORRECTLY 1. 4
1.3 4
3. INSTALLED THE MOTOR CORRECTLY 1.4 5
4. HUNG THE GATE CORRECTLY 1.5 5
5. CHECKED THE MANUAL RELEASE
SYSTEM 1.6 6
NOW STAGE 1 IS FULLY COMPLETED YOU ARE READY TO
BEGIN STAGE OF YOUR FROG AUTOMATION KIT
INSTALLATION
END OF INSTALLATION
STAGE 1

STAGE - WIRING & ELECTRICAL
.1 - Fitting the Control Panel in the Casing
8
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.

9
. - Wiring the Motor
THE FROG MOTOR ALWAYS COMES PREWIRED AND THE CONNECTIONS TO
THE MOTOR SHOULD BE MADE IN THE JUNCTION BOXES AT THE BASE OF
THE GATE POST (I.E OUT OF THE GROUND OR FOUNDATION CASING) AS
SHOWN IN FIG 3.
UNDER NO CIRCUMSTANCES MUST THE MOTOR BE DISCONNECTED FROM
THE GEARBOX AS THIS WILL INVALIDATE THE WARRANTY.
WHEN CONNECTING THE MOTOR TO THE CONTROL PANEL THE BLUE WIRE
ON THE MOTOR IS THE COMMON WIRE AND IS ALWAYS TO THE “W” ON
THE TERMINAL STRIP IN THE CONTROL PANEL. THE BROWN AND BLACK
WIRES ARE THE MOTOR DIRECTIONS AND ARE CONNECTED TO “X+Y” FOR
MOTOR 2. MOTOR 2 IS ALWAYS USED FOR SINGLE GATE
INSTALLATIONS.
ENSURE THAT THE MOTOR IS ADEQUATELY EARTHED.
Fig 7
U V W
MOTOR
EARTH
L1 L2 U V W E1 ES 10 11 1 2 3 5 7 C1

10
ZA4
.3 - 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 8
SAFETY
BEAM
RECEIVER
SAFETY
BEAM
TRANSMITTER
IF FITTING A SECOND ARC LINE OF SAFETY BEAMS THEN C & NC MUST BE WIRED IN “SERIES”
.4 - 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 9
NC
C

.5 - Wiring in the Tuned Antenna
.6 - Coding the Remote Controls
1. REMOVE THE BATTERY COVER & CASING OF THE REMOTE CONTROL
HANDSET TO REVEAL THE DIAGRAM BELOW
.7 - 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 1
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 11
11

END OF INSTALLATION
STAGE
BEFORE STARTING STAGE 3 -
Commissioning the Control Panel
PLEASE CHECK THAT YOU HAVE CORRECTLY:
Ref Page
1. FITTING THE CONTROL PANEL
IN THE CASING .1 8
. WIRED THE MOTOR AS SHOWN (Fig 7) . 912
3. WIRED IN THE SAFETY PHOTOCELLS
AS SHOWN (Fig 8) .3 10
4. INSERTED THE RADIO FREQUENCY
CARD AS SHOWN (Fig 9) .4 10
5. WIRED IN THE TUNED ANTENNA
CODED AS SHOWN (Fig 10) .5 11
6. PROGRAMMED THE REMOTE CONTROLS
AS SHOWN (Fig 11) .6 11
7. POWERED UP THE CONTROL PANEL .7 11
NOW STAGE IS FULLY COMPLETED YOU ARE READY TO
BEGIN STAGE 3 OF YOUR FROG AUTOMATION KIT
INSTALLATION
12

STAGE 3
COMMISSIONING THE CONTROL PANEL
3.1 - Initial Wiring & Control Panel Setup
13
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 12
3. INSERT THE ‘START-UP’ CAPACITOR INTO
THE CONTROL PANEL. THE TWO BLACK
WIRES SHOULD BE CONNECTED TO THE
CAPACITOR.
4. ENSURE THAT THE MOTORS ARE
ADEQUATELY EARTHED
ZA4
Fig 13

3. - Opening & Closing the Gate
2. ONCE YOU HAVE PROVED 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 14
Fig 15
Fig 16
Fig 17
5. SELECT DIPSWITCHES 1 & 2 OFF FOR
COMMISSIONING
6. ENSURE HARD WIRE LINK IS FITTED
BETWEEN TERMINALS 1 & 2 AND
2 & C1
14
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
L1 L2 U V W E1 ES 10 11 1 2 3 5 7 C1
ON
OFF 11

15
3.3 - Control Panel Adjustments
TRIMMER TL
1. TO SET THE TOTAL RUNNING TIME OF THE MOTORS, ADJUST
POTENIOMETER TL TO ALLOW THE MOTORS TO RUN FOR A FURTHER
5-7 SECONDS AFTER THE MOVEMENT CYCLE HAS BEEN COMPLETED
(I.E FULLY OPEN OR FULLY CLOSED)
2. CHECK THE SENSITIVITY OF THE GATE
BY TRYING TO PHYSICALLY STOP THE
GATE AND ADJUST THE POWER
SETTINGS ON THE TRANSFORMER
ACCORDINGLY. IF MORE POWER IS
NEEDED FOR A HEAVIER GATE 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 19
Fig 2

3.4 - Automatic Close & Activating Safety Photocells
FULLY ANTI-CLOCKWISE WILL APPROX. AUTOMATICALLY CLOSE THE GATE
AFTER 10 SECONDS AND FULLY CLOCKWISE WILL APPROX. CLOSE THE
GATE AFTER 0 SECONDS. A SENSIBLE SETTING IS ABOUT HALFWAY
(I.E 6 O’CLOCK POSITION) WHICH WILL AUTOMATICALLY CLOSE THE
GATES AFTER APPROX. 30 SECONDS.
6 O’CLOCK
TRIMMER
TCA
1. TO SELECT AUTOMATIC CLOSING,
SELECT DIPSWITCH 2 ON.
SET THE AUTOMATIC CLOSING TIME BY ADJUSTING POTENTIOMETER TCA
Fig 21
Fig 22
Fig 23
ON
OFF
11
2. FOR RE-OPENING DURING CLOSING.
REMOVE HARD WIRE LINK BETWEEN
2 & C1 AND INSERT SAFETY BEAM
WIRES AS SHOWN.
16
ES 10 11 1 2 3 5 7 C1
10 11 C NC

17
3.5 - Programming the Remote Controls
to the Control Panel
To use the remote control system, proceed as follows:
A) Turn power OFF and insert AF radio frequency board then turn
power back on
B) Code the transmitter. See the relevant instruction sheet
(See Fig 11)
C) To store the code on the circuit board Proceed as follows:
Press and hold down the YellowCH1 button on the radio receiver
card (the signal LED will start to flash)
At the same time transmit on the top button of your remote
control; keep both the top button and the yellow receiver button
pressed until the LED stops flashing and remains on constant to
indicate that the code has been successfully stored.
N.B. If you wish to change the code on your transmitter in the future,
simply repeat the procedure above with all the remotes on the
installation.
WARNING: Disconnect the power supply from the control board before
inserting OR removing the AF radio-frquency card from the
socket.

PLEASE CHECK THAT YOU HAVE CORRECTLY:
Ref Page
1. SET POWER SETTING, INSERTED MOTOR
CAPACITORS, SET DIPSWITCHES FOR
COMMISSIONING, ENSURE WIRE LINK
IS FITTED BETWEEN TERMINALS 1 &
AND & C1 3.1 1
. SET THE OPENING AND CLOSING TIMES
FOR GATES 3. 13
3. ADJUSTED THE CONTROL PANEL 3.3 14
4. IF REQUIRED, ACTIVATED AUTOMATIC
CLOSING AND SAFETY PHOTOCELLS 3.4 15
5. PROGRAMMED THE REMOTE TO THE
CONTROL PANEL 3.5 16
END OF INSTALLATION
STAGE 3
18

4. TROUBLESHOOTING GUIDE
A MULTIMETER WILL BE NEEDED
PROBLEM SOLUTION
GATE WILL NOT RESPOND
WHEN GIVEN A COMMAND
1. CHECK POWER SUPPLY TO THE
CONTROL PANEL.
2. CHECK CONTROL PANEL FUSES.
3. CHECK HARD WIRE LINK FITTED
BETWEEN TERMINALS 1 & 2.
4. CHECK THAT CAPACITORS ARE
FITTED AND WIRED CORRECTLY.
1. CHECK SAFETY BEAMS ARE WIRED
CORRECTLY. (IF MORE THAN ONE
SET OF BEAMS ARE FITTED THEY
MUST BE WIRED IN SERIES.)
2. CHECK THAT THERE IS POWER
GOING TO THE BEAMS, IF NOT
RESTORE POWER.
3. IF SAFETY BEAMS ARE NOT FITTED
ENSURE THAT A HARD WIRE IS
FITTED BETWEEN TERMINALS 2 &
C1.
4. REMOVE SAFETY BEAM WIRES 2 &
C1 FROM CONTROL PANEL AND
CHECK IF YOU HAVE A NORMALLY
CLOSED CIRCUIT COMING FROM
THE BEAMS.
1. MOTOR WIRES ARE WRONG WAY
ROUND. CHECK AND PROVE MOTOR
DIRECTION BY MOMENTORIALLY
PULSING TERMINALS 2 & 3. THE
GATE SHOULD OPEN UP. TURN
AUTOMATIC CLOSING OFF (DIP
SWITCH 2) UNTIL MOTOR
DIRECTION HAS BEEN PROVED.
WHEN COMMISSIONING
GATE AUTOMATICALLY OPEN
BUT DO NOT
AUTOMATICALLY CLOSE
GATE IS OPEN BUT WILL
NOT CLOSE AND GREEN LED
IS FLASHING
19
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