CAME GGT80AGS User manual

Automatic road barriers
GGT80AGS GGT80RGS GGT80ACS
GGT80AX4 GGT80AX6
INSTALLATION MANUAL
FA01384-EN
EN English

DEVICE MANUAL RELEASE
Releasing the device may be dangerous for the user, if the boom fastening has been damaged or if the boom is no longer intact, as the result of an
accident or installation error.
In these cases, the tensioned springs no longer guarantee that the boom is balanced. The boom may suddenly rotate when being released.
Manual release may cause the operator to move in an uncontrolled manner due to a mechanical fault or an imbalance.
With the gearmotor released, the operator does not work.

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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 is defined by the Machinery Directive
(2006/42/EC) as partly completed machinery. • Partly completed machinery means an assembly which is almost
machinery but which cannot in itself perform a specific application. • Partly completed machinery is only intended to be
incorporated into or assembled with other machinery or other partly completed machinery or equipment thereby forming
machinery to which the Machinery Directive (2006/42/EC) applies. • 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. • Check that the
temperature ranges given are suitable for the installation site. • Make sure that opening the automatic barrier does not
constitute a hazard. • Do not install on slopes i.e. any surfaces that are not perfectly level. • Do not install the operator on
surfaces that could yield and bend. If necessary, add suitable reinforcements to the anchoring points. • 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-off device along the power supply that is compliant with the installation rules. It should
completely cut off the power supply according to category III surcharge conditions. • Demarcate the entire site properly
to prevent unauthorised personnel from entering, especially minors. • In case of manual handling, have one person for
every 20 kg that needs hoisting; for non-manual handling, use proper hoisting equipment in safe conditions. • When the
operator is being fixed in place, it may be unstable and overturn. Be careful and do not lean on it until it is fully fastened
in place. • Use suitable protection to prevent any mechanical hazards due to persons loitering within the operating range
of the operator. • The electrical cables must pass through special pipes, ducts and cable glands in order to guarantee
adequate protection against mechanical damage. • Make sure that the moving mechanical parts are suitably far away
from the wiring. • The electrical cables must not touch any parts that may overheat during use (such as the motor and
transformer). • 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 the passage is wider than 3 m, you must
use a fixed support for the boom. • 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 affixed 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
staff, 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.

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Main points of danger for people
Risk of trapping hands.
No transiting.
DISMANTLING AND DISPOSAL
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
803BB-0180
GGT80AGS - Automatic barrier with gearmotor 24 V DC with encoder; painted galvanised steel cabinet; accessories available. Balance springs included.
803BB-0220
GGT80RGS - Automatic barrier with gearmotor 24 V DC with encoder; painted galvanised steel cabinet; accessories available. Balance springs included.
803BB-0250
GGT80AX4 - Automatic barrier with gearmotor 24 V DC with encoder; satin-finish AISI 304 steel cabinet; accessories available. Balance springs included.
803BB-0270
GGT80AX6 - Automatic barrier with gearmotor 24 V DC with encoder; satin-finish AISI 316 steel cabinet; accessories available. Balance springs included.
803BB-0290
GGT80ACS - Automatic barrier with gearmotor 24 V DC with encoder; custom-RAL painted galvanised steel cabinet; accessories available. Balance springs included.
Intended use
Ideal solution for apartment blocks and industrial applications
Any installation and/or use other than that specified in this manual is forbidden.
Usage limitations
MODELS GGT80AGS GGT80RGS GGT80AX4 GGT80AX6 GGT80ACS
Max. net clearance width (m) 7,8 7,8 7,8 7,8 7,8
Technical data
MODELS GGT80AGS GGT80RGS GGT80AX4 GGT80AX6 GGT80ACS
Power supply (V - 50/60 Hz) 230 AC 120 AC 230 AC 230 AC 230 AC
Maximum current draw (mA) 1,1 2,2 1,1 1,1 1,1
Motor power supply (V) 24 DC 24 DC 24 DC 24 DC 24 DC
Standby consumption (W) 77777
Power (W) 300 300 300 300 300
Colour 7024 7024 - - RAL X
Operating temperature (°C) -20 ÷ +55
(-40 with item
001PSRT01)
-20 to +55
(-40 with item
001PSRT01)
-20 ÷ +55
(-40 with item
001PSRT01)
-20 ÷ +55
(-40 with item
001PSRT01)
-20 ÷ +55
(-40 with item
001PSRT01)
Torque (Nm) 600 600 600 600 600
Opening time at 90° (s) 4 ÷ 8 4 ÷ 8 4 ÷ 8 4 ÷ 8 4 ÷ 8
Cycles/hour 160 160 160 160 160
Cycles/day 2500 2500 2500 2500 2500
Protection rating (IP) 54 54 54 54 54
Insulation class IIIII
Weight (kg) 90 90 90 90 90
Fuse table
MODELS GGT80AGS GGT80RGS GGT80AX4 GGT80AX6 GGT80ACS
Line fuse 1.6 A-F 3.15 A-F 1.6 A-F 1.6 A-F 1.6 A-F
Accessory fuse 2 A-F 2 A-F 2 A-F 2 A-F 2 A-F
Control board fuse 4 A-F 4 A-F 4 A-F 4 A-F 4 A-F
Motor fuse 10 A-F 10 A-F 10 A-F 10 A-F 10 A-F

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Description of parts
Barrier
1Cover
2Boom anchoring plate
3Intermediate plate
4Fastening flange
5Anti-shearing cover
6Photocell holes
7Lock for release
8Cabinet
9Inspection hatch
10 Inspection-hatch lock
11 Control panel
12 Safety microswitch with cover open
13 Mechanical stop for the boom adjustment
14 Lever arm
15 Gear motor with encoder
16 Auxiliary
17 Line fuse
18 Power supply terminal board
19 Anchoring plate
20 Anchoring bracket
21 Boom profile end cap
22 Spring anchoring pin
23 001G06080 - Balance spring Ø 55 mm.
24 Released gearmotor safety microswitch
25 DIN rail

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Control board
1Programming buttons
2Terminal board for motor power supply
3Display
4Connector for plug-in radio frequency card (AF)
5Terminal board for connecting the antenna
6Terminal board for BUS accessories
7Connector for the R700 or R800 decoding card
8RSE_1 connector for RSE card
9Terminal board for connecting the keypad selector
10 Terminal board for connecting the transponder selector switch
11 Terminal board associated with the RSE_1 connector for paired, alternate or
CRP connection
12 Terminal board associated with the RSE_2 connector for CRP connection, IO
485 card or Modbus RTU interface
13 Terminal board for connecting the electric lock
14 Terminal board for connecting the safety microswitch with cover open and
gearmotor released (NC contact)
15 RSE_2 connector for RSE card
16 Terminal board for connecting the warning LED strip
17 Terminal board for connecting control and safety devices
18 Terminal board for connecting the encoder
19 Accessories fuse
20 Terminal board for barrier status*
21 Control board fuse
22 Terminal board for power supply to the control board
23 Motor fuse
24 Connector for CAME KEY
25 Memory Roll card connector
* Only for ZL392 boards, version B
NM
AB
S1 GND
A B GND
A B GND
EB EB
024
+E -
017
TAMPER
BUS
10 11 E1 TS 1 2 3 3P 4 5 7 2 CX CY CZ +RG
FCA CM1 FCC CM2
1
3
2
4
5
6
7
8
9
10
11
12
13
14
22
19
16 151718
24
23
21
20

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Size
482
1222
913
max. 7800 381
249
73
116
416
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
Power supply 120 V AC 3G x 1.5 mm² 3G x 2.5 mm²
24 V AC/DC flashing beacon 2 x 1 mm² 2 x 1 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
24 V DC electric lock 2 x 1 mm² 2 x 1 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.
To connect the antenna, use RG58 cable (up to 5 m).
For installation in an outdoor environment, use cables with properties at least equivalent to those of type H05RN-F (with designation 60245 IEC 57).
For installation in an indoor environment, use cables with properties at least equivalent to those of type H05VV-F (designation to 60227 IEC 53).
If the cable lengths differ 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.
For paired and CRP connection, use a UTP CAT5 cable. Maximum length 1000 metres.
Single branch length (m) max. 50 m
BUS cable 2 x 0.5 mm²
The total length of all branches can be a maximum of 150 m.
The cable cannot be shielded.
Wind resistance
The table shows the boom wind-load resistance.
The value relates to the boom only and does not refer to any applicable accessories.
Resistance class with reference to the EN 13241 standard.
Type Boom 4.4 m Boom 6.4 m Boom 8 m
Resistance class 4 3 2
Wind pressure [Pa] 1100 600 400
Maximum wind speed [km/h] 160 120 100

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INSTALLATION
The following illustrations are examples only. The space available for fitting the operator and accessories varies depending on the area where it is
installed. It is up to the installer to find the most suitable solution.
In case of manual handling, have one person for every 20 kg that needs hoisting; for non-manual handling, use proper hoisting equipment in safe conditions.
When the operator is being fixed in place, it may be unstable and overturn. Be careful and do not lean on it until it is fully fastened in place.
Preliminary operations
If the flooring does not allow the device to be fastened in a solid and stable way, lay a cement slab.
Dig a hole for the foundation frame.
Set up the corrugated tubes needed for the wiring coming out of the junction pit.
The number of tubes depends on the type of system and the accessories that are going to be fitted.
460
240
380
140
500
600
400
Laying the anchoring plate
Set up a foundation frame that is larger than the anchoring plate.
Fit an iron cage in the foundation frame to reinforce the concrete.
Assemble the anchoring braces to the plate.
Fit the anchoring plate in the iron cage.
The tubes must pass through the existing holes.
Cast cement into the foundation frame.
The plate must be perfectly level and the screw threads completely above surface.
Wait at least 24 hours for the cement to dry.
Remove the foundation frame.

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Fill the hole with soil around the concrete block.
Remove the nuts from the screws.
Thread the electrical cables into the tubes so that they protrude by about 1500 mm.
Preparing the barrier
With the inspection hatch open, the operator does not work.
Fastening the barrier

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Changing the boom opening direction

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Boom installation
Insert the reinforcement inside the boom.
First install the LED strip (where applicable), ONLY THEN fix the flange and the intermediate plate.
Tighten the screws firmly.

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1Cut the slot-cover profiles to the same size as the boom slot minus 10 millimetres.
2Insert the slot-cover profiles into the grooves on both sides of the boom.
3Insert the anti-impact rubber profile into the groove.
4Cut off the excess part of the profile.
5Use the screws to fasten the boom end cap.
6Fit the anti-shearing protective cover onto the boom-attachment cover and fasten it using the screws supplied.
10

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Choosing the hole for fixing the balance spring
Passage width clearance (m) 4,00 < 4,50 4,50 < 5,00 5,00 < 5,50 5,50 < 6,00 6,00 < 6,50 6,50 < 7,00 7,00 < 7,80
Boom with LED strip A A B A A A A A A B B
Boom with LED strip and single skirt* B A A A A B B B B B B -
Boom with LED strip and full-height skirt A A A A B B B B ---
Boom with LED strip and swing rest A B A A A A A A A A -
Boom with LED strip, single skirt and swing rest A A A A A A ----
Boom with LED strip, full-height skirt and swing rest A A B B B B ----
Simple boom means the boom complete with slot cover, cap and rubber profile.
If the passage is wider than 4 m, you must use a support for the boom (fixed or mobile).
Single skirt (803XA-0340):
- max 2 modules for a 4 metre boom
- max 3 modules for a 6 metre boom
- max 4 modules for up to a 7 metre boom
Full-height skirt (803XA-0350):
- max 2 modules for a 4 metre boom.
- max 3 modules for a 6 metre boom.

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Assembling the balance spring
1Release the gearmotor.
2Position the boom vertically.
3Lock the gearmotor
4 5 6 Assemble the anchoring pin and fix it on the lever arm.
7Tighten the eyelet tie rod to the lower part of the spring.
8Screw the spring to the anchoring pin.
9Hook the eyelet rod onto the anchoring bracket.
8

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Balancing the boom
1Release the gearmotor.
2Manually turn the spring to increase or reduce the traction. The boom
should stabilise at 45°.
Where there are two springs, carry out the procedure on both springs at
the same time.
3Fasten the locknut.
Position the boom vertically.
4Lock the gearmotor
Check the proper working state of the spring. When the boom is vertical,
the spring is not taut. When the boom is horizontal, the spring is taut.
4

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Determining the travel end points with mechanical limit switches
Check that the boom is parallel to the road surface when it is in the closed position and at about 89° when it is in the open position.
Correct the boom’s horizontal position
Release the gearmotor.
Open the inspection hatch.
1Turn the mechanical stop until you reach the desired boom position.
2Fasten the mechanical stop with a locknut.
Lock the gearmotor
+
_
2
1
1

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Correct the boom’s vertical position
Release the gearmotor.
Open the inspection hatch.
1Turn the mechanical stop until you reach the desired boom position.
2Fasten the mechanical stop with a locknut.
Lock the gearmotor
+_
~1°
~89°
11
2

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ELECTRICAL CONNECTIONS
Passing the electrical cables
The electrical cables must not touch any parts that may overheat during use (such as the motor and transformer).
Make sure that the moving mechanical parts are suitably far away from the wiring.
Power supply
Make sure the mains power supply is disconnected during all installation procedures.
Before working on the control panel, disconnect the mains power supply and remove the batteries, if any.
Connecting to the electrical network
FLine fuse
LPhase
NNeutral
Earth
EFerrite
Apply the ferrite supplied to the power supply cable.
Ferrite type p.n. ECQK922091.
The cable must pass through the ferrite twice (2 turns).
F
230 V AC
50/60 Hz
E
Power 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.
The sum of the power draw for the connected
accessories must not exceed 40 W.
10 11 E1 TS 1 2
3
E
1
T
S
1
2
3

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Maximum capacity of contacts
Device Output Power supply (V) Power (W)
Accessories 10 - 11 24 AC 40
Additional light 10 - E1 24 AC 25
Flashing beacon 10 - E1 24 AC 25
Operator status warning light 10 - 5 24 AC 3
RGB LED strip +RG 24 DC 12
Electric lock Eb- - Eb+ 24 DC 5
Devices with BUS CXN system
The CXN CAME system is a two-wire non-polarised communication BUS which allows you to connect up all compatible CAME devices.
Connection to the BUS can be in a chain, star or mixed formation.
Once the system has been wired, and after having set the address on each device, the function of each accessory can be configured on the control panel. This
method allows you to configure the set-up immediately without having to do so later and intervene directly on the accessories and system wiring.
The CXN BUS can support control devices, photocells, safety devices, beacons and gateways at the same time.
Cabling
1Chain connection
2Star connection
3Mixed connection
Cable type
We recommend using a FROR 2 x 0.5 mm cable, maximum 50 m in length from the control board.
Single branch length (m) max. 50 m
BUS cable 2 x 0.5 mm²
The total length of all branches can be a maximum of 150 m.
The cable cannot be shielded.
Maximum number of devices that can be connected at the same time
Type of device Maximum number of devices
Keypad selectors and transponders 7
Photocell pairs 8
Flashing beacons 2
Do not connect anything other than CAME BUS accessories.