Corkill Systems 2014 User guide

Copyright June 2014 – Steve Corkill
This manual subject to copyright and not to be copied without the express permission of Corkill Systems Limited
CSLRHLG-MANUAL-2014.DOC Page 117 April 2014
CSL ELECTRONIC
BACKING
GATE CONTROLLER
2014 Model
INSTRUCTION
&
INSTALLERS
MANUAL
Electronic System Designed and Manufactured
By
CORKILL SYSTEMS LIMITED
Phone [phone]
A Q-Base Registered Company
These instructions are to be used in conjunction with
the Danfoss operating instruction manual provided.

Copyright June 2014 – Steve Corkill
This manual subject to copyright and not to be copied without the express permission of Corkill Systems Limited
CSLRHLG-MANUAL-2014.DOC Page 217 April 2014
THE CSL HIGH LIFT GATE CONTROLLER ELECTRONIC SYSTEM
2014
INTRODUCTION
The system is driven by a Danfoss VLT2800 series variable speed drive (VLT) which supplies
230 volt three phase to the motors at preset frequencies. The VLT has a filter fitted to protect
the unit from incoming voltage irregularities and noise and to limit interference on the output.
The VLT unit is controlled by an Omron CP1L-L20DR-A Programmable Logic Controller
(PLC) which determines commands from the microswitches on the gate and the main push-
button interfaces.
SUPPLY
Supply is Single Phase 220 - 240 Volt 50/60 Hertz, Voltage tolerance is 220 Volts ±10%.
Specialised voltage units can be built to order.
A 2.5mm single phase supply fused or circuit breaker protected to 16 Amps is required at the
Main Junction Box at the yard end of the Dairy. The cable should be of the specified size as a
minimum to prevent volt drop in the system due to the long distance normally between the
Main Switchboard and the gate.
It is not recommended to connect the unit via an Earth Leakage device (RCD); the controller
monitors earth constantly to protect the motors, and has a leakage of approximately 8
milliamps.
INSTALLATION
The Multicore cable supplied should be attached to the cable rollers at 1200mm intervals, roll
this cable out with no kinks prior to attaching to the rollers to prevent twisting. Connections
are as per the numbers in the cable and at the connections in the Main Junction Box and the
Main Control Panel. Diagrams are on the following pages.
The Push-Button Station cable is colour coded and should be connected at the Main
Junction Box as per the Low Voltage diagram. If Radio Interference is likely to be severe from
non-filtered Variable Speed Drives in the vicinity, connect the screen of this cable to the Earth
terminal.
Micro switches on the gate are Extra Low Voltage and to be wired to the labelled terminals
in the Main Control Panel, all commons wire to Terminal #3, there are two of these terminals
for convenience. They are mounted on the side of the gate closest to the control box.
The TER Rotary Limit Switch is designed to be mounted at the top of the gate in the end of
the shaft of the lift motor.
The limit switch is designed to sit on the spring bracket.
DO NOT SCREW THE LIMIT SWITCH TO THE BRACKET.
The grub screw in the gear box shaft is sufficient enough to hold the limit switch in place;
damage will result to the switch if this is attempted.
Care should be taken to ensure the covers are correctly refitted on the micro switches also
that all glands are tight on the switches silicon may be applied to these joints as an extra
precaution to prevent moisture ingress.

Copyright June 2014 – Steve Corkill
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CSLRHLG-MANUAL-2014.DOC Page 317 April 2014
The Motors are to be wired in EMC type screened cable and is recommended using steel
glands to connect the cable screens at both the control box and the motors to comply with C-
Tick requirements. The earth conductor MUST also be attached at both ends. The motors
must be wired in DELTA configuration (230 volt). See the High Voltage Diagram instruction in
the lower right corner.
An example of a metal gland is shown below:
Installation of metal glands and screened cables is an essential factor in lowering the SCC in
the dairy plant.
The minimum size of the conductors to the motors should be 1mm. Do not undersize cables,
larger is better to assist removal of RFI.
The above is also critical if cow ID systems are in use or being contemplated. The screen
should be retained over the cable as close as possible to the termination.
COMMISSIONING
Turn the “main” switch to the “ON” position and the VLT screen will go through a brief
diagnostic phase and then read out “Fr 00.0”. The PLC will have some inputs lit according to
which micro switches are activated. Input “00” is the “Stop” circuit and will always be lit unless
a “Stop” button is held in. See the specific chart for the PLC Inputs and Outputs.
1. Operate the “UP” Button and check that the Lift Gate travels to the fully UP position and
stops. During the down travel in either an option or using the down push button. The gate will
travel down for 7.5seconds, stop for 3 seconds for cows to part in the yard, then continue to
travel down. This feature is designed to capture half the cows in the yard.
2. Ensure all rails are clear of obstacles, stand clear of the unit and test the “FORWARD”
operation and micro switch. Repeat with the “REVERSE” operation. The siren will operate
only in the Forward mode.
3. Repeat Steps #1 and #2 above at the Remote Push-button station, the operations should
be identical.
SEQUENCE OPERATION
There are several available programs/ options for the gate controller as follows.
Standard program/ options:
1.Standard Program
a) Press the “Gate up” button, gate travels up until “up” limit switch operates or “stop” button
is pushed.
Same for “Down”, “Forward” and “Reverse”.
1. (A)Up/Down Follow Command
If the up or down push button is pressed followed by either forward or reverse within 3
seconds. The gate will firstly go in either up or down direction, until the micro switch is
activated, and then in either forward or reverse.

Copyright June 2014 – Steve Corkill
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1. (B) Pressure Reverse Switch
This option stops the gate overcrowding the cows. As the gate moves forward and starts to lift
on the back of the cows, it hits a micro switch and stops the gate moving forward and
reverses for 3 seconds. This feature is fitted to all gates.
Note: that the pressure reverse switch only works when the gate is fully down it also operates
in the “Cycle” and “Syncro” programs.
1. (C) Down Delay
During the down travel in either an option or using the down push button. The gate will travel
down for 7.5 seconds, stop for 3 seconds for cows to part in the yard, then continue to travel
down. This feature is designed to capture half the cows in the yard.
Note: the down delay will only operate if the down operation commences from the gate upper
limit and will operate in every mode except in wash mode.
1. (D) Pull Switch, Forward Motion
The pull switch is to stop or start the backing gate. Activation of the pull switch will not reset
the “Syncro” or “Cycle” program but will allow the gate to move forward.
Note: 2. Forward motion can also be controlled by pull switch when the gate is in one of the
optional pulse or cycle programs.
1. (E) Gate Brake, DC Hold Program
The gate has a special program embedded within the gate to lock the shaft of the motor after
travel has completed this feature will stop the gate from rolling back down the yard on sloping
yards and if the gate is stopped during the down travel.
Motor over run can some times be a problem on larger wider gates because of the inertia and
weight of the gate so this feature will also stop that from happening.
Note: at the end of any movement the gate brake will operate for 3 seconds and no button
can be pressed in that time to commence operation to give the gate time to brake.
1. (F) Reverse Down Safety
This program has a special timer to stop the gate from travelling backward to far while the
gate is down to avoid a second herd in the yard behind from getting crushed and will limit the
gate from travelling back for six seconds this can be over ridden by holding down the reverse
button for one second The gate will emit a beep to indicate the reverse safety has been
overridden.
1. (G) Off Limit Safety Timer
This program has a special timer to stop the gate if it takes more than 5 seconds to get off the
safety limit in case something goes wrong or the gate is stalled or jammed. The gate will
alarm indicating that a fault has occurred by emitting 3 short tones and gap being either the
down siren or the forward siren to indicate the directional limit at fault.
1. (H) Opposing Limit Safety Timer
This program has a special timer to stop the gate if it takes more than 300 seconds (or 600
seconds during wash) to get to the apposing for/rev limit or if it takes more than 25 seconds to
get to the apposing up/down limit.
This program is designed in case something goes wrong or the gate is stalled or jammed. The
gate will alarm indicating that a fault has occurred by emitting 3 short tones and gap being
either the down siren or the forward siren to indicate the directional limit at fault.
1. (I) Bypass mode
This program has a Bypass mode if one of the limit switches should fail to enable the gate to
temporally operate, to enter this mode press in the stop button and turn on the main gate
controller until the siren sounds a one second pulse.
In this mode you can press the direction buttons and the gate will only move for as long as
you hold the buttons down and it will ignore the limit switch so be careful.
NOTE: the optional programs will not operate in this mode as it is assumed the limit or limit
switches are faulty which may cause undesired operation of the gate.
Bypass mode will have a maximum run time of 10 seconds as a safety per button operation.

Copyright June 2014 – Steve Corkill
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CSLRHLG-MANUAL-2014.DOC Page 517 April 2014
1. (J) Override mode
This program has a override mode if one of the limit switches should fail to enable the gate to
operate overriding the faulty limit, at any time you can press the direction buttons and the gate
will only move for as long as you hold the buttons down and it will ignore the limit switch so be
careful.
Override mode will have a maximum run time of 10 seconds as a safety per button operation.
1. (K) Quick
This program has two speeds in reverse and forward mode. When the “REVERSE” or
“FORWARD” button is pressed the first time the speed is 50 Hz when actuated a second
time, the gate motor will accelerate and travel at a higher speed (75 Hz).
Note the Reverse down safety must first been overridden to enable this feature the gate will
emit a beep to indicate slow speed and two beeps to indicate fast speed.
1. (L) Cycle Program
Press the “CYCLE” button the lift gate travels down until the limit switch operates. The gate
moves forward an incremental amount after a set period in a continuous cycle, the distance
travelled per pulse or the delay pulse can be altered by carefully adjusting the preset
analogue pot see pot selection and program adjustment below on how to alter this.
Note: The “DOWN DELAY” option functions in this option.
1. (M) Pulse Program
This program is the same as the Cycle program except the gate will pulse only once when the
“PULSE” button is pressed.
The distance travelled per pulse can be altered by carefully adjusting the preset analogue pot
see pot selection and program adjustment below on how to alter this.
Note: The “DOWN DELAY” option functions in this option.
1. (N) Synchronisation Program
Press the “SYNC” button and the lift gate will lower then count the sync micro switch on the
platform, Bail gate or a photo eye sensor on the exit race. The amount that the gate will count
pulses can be set by adjusting the preset analogue pot with a range of 1-20 pulses. The gate
will then move forward, an incremental amount, the distance travelled per sync and the
number of counts can be altered by carefully adjusting the preset analogue pot see pot
selection and program adjustment below on how to alter this.
Note: the counter operated switch will only activate the sync forward after the syncro button is
depressed.
Note: The “DOWN DELAY” option functions in this option.
1. (O) HB Synchronisation Program
Press the “HBSYNC” button and the lift gate will lower then wait for the sync micro switch on
the gate head Bail to the exit race. The gate will wait for 60 seconds before moving forward,
an incremental amount, the distance travelled per HB Sync can be altered by carefully
adjusting the preset analogue pot see pot selection and program adjustment below on how to
alter this.
Note: the counter operated switch will only activate the sync forward after the hb sync button
is depressed.
Note: The “DOWN DELAY” option functions in this option
1. (P) Wash Program
when the “WASH” button is pressed either forward or reverse the gate will go up and travel to
the opposing limit and come down, it will then drive at a slow speed while washing the yard
until it gets to its corresponding limit the gate will then return to the back of the yard in the up
position ready for the next milking.

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CSLRHLG-MANUAL-2014.DOC Page 617 April 2014
The wash program can also be used to turn on the wash down pump during the washing
phase of the gate wash program using the wash output terminal on the slave unit plc within
the junction box.
1. (Q) Wash While Down Program
This operates the same as the STD program except that when the gate is down and the gate
is travelling either forward or reverse the wash feature of the gate will operate.
Optional Program / options’s
These options must be specified at the time of ordering and can not be enabled in the field
but a simple program upgrade and slight wiring changes can enable them please contact CSL
for more information
2. Midway Drain Wash Program
When “WASH” button is pressed the gate will travel up until the limit switch operates.
The gate then moves forward at high speed to the front of the yard then travels down and
then slowly backwards to the centre of the yard. When the midway microswitch is operated or
the centre timer is reached the gate will travel up then reverse at normal speed to the back of
the yard then travel down and then forward slowly to the centre of the yard. When the
midway microswitch is operated or the centre timer is reached the gate will travel up and then
reverse at high speed to the back of the yard and come to rest.
3. Round Yard
Works the same as a normal gate but is used on a straight yard with a curved section at
either the end of the yard. When the curved section microswitch is operated the gate will stop
one drive motor and drive around the bend.
All other functions operate as normal.
1. (J) Self Alignment Feature
The self alignment feature operates the same as any given gate except that it has the ability
to align the gate left or right side individually forward or reverse if the gate becomes
unaligned.
This option will require an upgrade gate controller and cant be added to an existing gate
controller please contact CSL if you believe you require this.
Note: only one Wash Program and Optional program option can be used at once but just
about any other or combination of programs are available.
Note1: During the wash cycle and syncro functions the gate will intermittently beep every 30
seconds to warn you the gate is still in automatic operation.
Custom Programs.
If you have a feature you wish to implement that is not covered in this manual please contact
this we will be happy to modify or create this feature for you we have many custom programs
that are not outlined in this manual that we could offer you to suit your needs.
DISTANCE ADJUSTMENT PROCEDURE:
To adjust the distance the gate travels in any of the optional programs (pulse/cycle/sync and
hbsync) turn the pot clockwise to set the desired distance timer.
The default distance is 5 seconds when the pot is set to the anti clockwise limit the pot will
give adjustment from 5 to 30 seconds.
Program specific adjustment procedure (fake pot setup):
To adjust the cycle delay timer, or the sync count value press and hold in the “STOP”, “UP“
and “DOWN” button until the gate beeps then turn the pot clockwise to set the desired timer
or counter.

Copyright June 2014 – Steve Corkill
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CSLRHLG-MANUAL-2014.DOC Page 717 April 2014
The default values and adjustment range depends on the option selected as in the following
table:
Program selected
Default setting
Adjustment range
cycle
1 min between pulses
1min-10min
sync
1 sync input
1-20 counts
FOR PULSE /HB SYNC
Selection of Pulse/HBSync is done by setting the fake pot fully anti clockwise (a different
beep tone will sound when Pulse/HBSync is enabled.)
FOR CYCLE /SYNCRO
Selection of Cycle/Syncro is done by setting the fake pot off the stop limit and clockwise to
set the amount of micro switch pulses per gate sync and delay time per cycle (a different
beep tone will sound when Cycle/Syncro is enabled.
FOR FORWARD WASH
Selection of Forward Wash is done by wiring the wash button across the up and forward
contacts .
FOR REVERSE WASH
Selection of Reverse Wash is done by wiring the wash button across the up and reverse
contacts
Notes: After adjusting the fake pot you must re adjust the distance pot back to the desired
distance settings.
The Wash Program and Optional program above are common to most gates and can be
changed at will any other program must be specified at the time of ordering and can not be
changed in the field.
If your gate did not accompany any optional programs at the time of ordering you must order
an upgrade program package.
OMRON Programmable Logic Controller
The Omron PLC can be altered in the field with some exceptions please phone Corkill
Systems to talk to a Technician for advice.
Gate upgrade programs are available by contacting Corkill Systems Limited on 06 761 7531.
Upgrade gate programs come in the form of a memory stick that plugs into the plc and are
returned when programming is complete and may be preformed by any one but if additional
wiring is needed a registered electrician, or a Corkill Systems technician will be required to do
the necessary changes to the gate to accompany the program change.

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CSLRHLG-MANUAL-2014.DOC Page 817 April 2014
DATACABLE UPGRADE.
There is also an optional upgrade that replaces the multicore cable up the yard with a special
cable. This cable has both 3 phase power and 2 wire data communications cable embedded
inside it to relay information between the junction box and the gate simplify installation.
This opens up the gate to enable additional features such as:
* Water pump control
* Solenoid valve control
* Direction indicator lamps
* Function indicator lamps
* Warning siren tones.
* longer yards from lighter cable and 3 phase upgrade
* Future expansion possibilities
* PC and PLC control possibilities
* Wireless control (See below)
This upgrade consists of a communication module to fit to the gate and a replacement
junction box and cable, this enables more information to exchange between junction box and
gate than the standard cable will allow.
WIRELESS DATA CABLE UPGRADE.
This is the same as the special cable but it enables control over a radio control interface.
DATA LINK CONTROL INFO.
The data cable option is preformed using the Hostlink protocol on top of RS-485 cabling.
If you wish this could be controlled by a drafting gate system such as pro-track we can
provide information on interfacing with the gate from a plc or computer if you wish to
implement such a control system.
We can provide you with sample code to interface with this using an Omron plc if you wish, I
suggest you contact us regarding this.
ALARMS
If the unit should go into Alarm mode, the gate will stop and the siren will operate with a single
tone, all buttons will be locked until the Alarm has been reset. The following will cause the
Alarm to operate.
1. Overload on the Drive Motors
If either Electronic Over Current Relay (EOCR) trips due to the gate being obstructed, the
Red LED will light on one of the pair of units indicating a fault. These can be reset by the
Resets on the EOCR’s themselves or by turning the Isolator off for 1 minute. If one EOCR
repeats the alarm frequently, it may need slight adjustment to either the time or current
settings.
2. VLT Alarm
There are several potential Alarm situations in the controller as the unit is monitoring both
itself and the connected motors constantly (even when the motors are in the Stop position), it
is also monitoring temperatures and looking for ground faults and short circuits. The screen
will give a numeric message describing the fault. Reset by turning the Isolator off for at least 1
minute. All fault messages are on page 55 and 60 in the VLT2800 manual supplied. If the
fault persists call for service on 06 761 7531 or contact a Danfoss Service Agent. Please note
the VLT numeric message and which PLC inputs and outputs are lit before calling or have a
cell phone available at the gate to be able to check the diagnostics by phone.
3. PLC Alarm
Output “00” will be flashing on the PLC, this indicates a fault in the system.
There are different alarm tones depending on the fault condition.

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4. Faulty Stop Circuit
if there is a fault in the stop circuit the alarm siren will sound.
5. Faulty Limit Switches
if there is a fault where both of either the up/down or forward/ reverse limit switches are open
at any given time the siren will sound indicating a fault with the gate or incorrectly adjusted or
installed limit switches.
With all Alarms, check to see where the fault is coming from before resetting, if the fault
persists, call for service with details of the fault.
ELECTRICAL SERVICING
1. Low Voltage
All buttons circuits can be checked by pressing the button and observing the corresponding
PLC input LED as per the following chart. When output LED’s are lit, those output terminals
will be at + 24 VDC relative to VLT Terminal #20. All outputs are supplied by VLT Terminal
#12. The PLC has a 24 VDC separate output which is used to power the alarm circuit.
PLC indicator LED Status Chart (ON = Lit, OFF = Not Lit)
BUTTON
PUSHED
00 (NC)
STOP
01 (NO)
UP
02 (NO)
DOWN
03 (NO)
FORWARD
04 (NO)
REVERSE
05 (NO)
PULL
NO
ON
OFF
OFF
OFF
OFF
OFF
YES
OFF
ON
ON
ON
ON
ON
SWITCH
ACTIVATED
06 (NO)
PRESSURE
07 (NC)
UP
M/SW
08 (NC)
DOWN
M/SW
09 (NC)
FORWARD
M/SW
10 (NC)
REVERSE
M/SW
11 (no)
SYNC
NO
OFF
ON
ON
ON
ON
OFF
YES
ON
OFF
OFF
OFF
OFF
ON
Fault Loop (00), this circuit includes alarm modes from the EOCR’s and VLT Alarm Relay or a
open “Stop” button circuit or faulty micro switches.
Please note that all micro-switches are in the Normally Closed position between stop
positions and normally open when at the stop limit except the breech switch.
2. High Voltage
WARNING! The VLT can retain high voltages for a period after the power has been isolated
due to the large capacitors in the power supply circuit. Wait at least 4 minutes before touching
any parts.
A 1 Amp glass fuse protects the PLC and EOCR’s, this is located adjacent the PLC in a DIN
type fuse holder.
If checking motors with the power to the Main Control Panel, disconnect the motor plug from
the VLT before touching any motor terminals as the VLT outputs a small voltage to the motor
terminals even with the motor stopped to monitor the motor condition.
PROGRAMMING the Danfoss VLT2807 Controller
If the VLT program has been inadvertently altered or requires custom settings, the following is
a program sheet giving the values changed from the Danfoss factory settings. Instructions to
alter parameters are also in the VLT2800 Operating Instructions.
A hand programming unit (LCP) and cable to plug into the VLT communications port can be
“lent” if programming is required to be done from scratch and the service person is
uncomfortable with programming
#
Parameter Name
Set-up 1
Lift Motor
Set-up 2
Drive
Motors
Set-up 3
Drive
Motors
(Wash)
Set-up 4
Drive
Motors
(Wash)
Parameter
Setting
004
Active Set-up
5
5
5
5

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005
Programming
Set-up
5
5
5
5
(Note 1)
014
Local Stop
1
1
1
1
102
Motor Power
0.55kW
0.75kW
0.75kW
0.75kW
103
Motor Voltage
230
230
230
230
105
Motor Current
2.5
6.0
6.0
6.0
123
Min.f.func.stop
0.1Hz
0.1Hz
0.1Hz
0.1Hz
126
Dc braking time
3.0s
3.0s
3.0s
3.0s
127
Dc brake cut in
frequency
3 Hz
3 Hz
3 Hz
3 Hz
128
Mot.therm protec
4
0
0
0
132
Dc brake voltage
25%
25%
25%
25%
200
Output Frequency
Range
1
1
1
1
205
Maximum
Reference
100
100
100
100
(Note 2)
207
Ramp-up Time
1.0
1.0
1.0
1.0
Seconds
208
Ramp-down Time
1.0
1.0
1.0
1.0
Seconds
215
Preset Reference
1
55%
75%
75%
75
note 3
216
Preset Reference
2
-55%
-75%
-75%
-75
note 3
217
Preset Reference
3
-55%
50%
50%
20%
note 3
218
Preset Reference
4
-55%
-50%
-50%
-20%
note 3
302
Input Terminal
#18
22
22
22
22
303
Input Terminal
#19
23
23
23
23
304
Input Terminal
#27
33
33
33
33
305
Input Terminal
#29
31
31
31
31
307
Input Terminal
#33
32
32
32
32
323
Relay Output 1-3
10
10
10
10
405
Reset Function
11
11
11
11
Programming Notes
To enter programming mode, press “Quick Menu” and “+” simultaneously, screen will flash.
Move to required parameter using “+” and “-“ keys.
To view data, press “Change Data” at the desired parameter number. At this point data value
can be changed, change data by using “+” or “-” and save by pressing “Change Data” again
within 15 seconds of making the changes.
Note 1:
At the normal “Stop” position, controller is in “Set-up One”, this is the program for the Gate
Lift Motor, any parameters relating to lift operation can be changed at this point. To change
parameters in the Gate Forward & Reverse mode, change the data value in “005” to data
value “2” and save. This will need to be changed back to “5” upon completion of changes.
Note 2:
Raising or lowering the data values in this parameter will alter the overall travel or lift speeds.
Note 3:
This parameter alters motor speed and direction depending on which program is used:
Note 4:

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The lift gate DC Hold programming is enabled by default but on larger gates increased current
may be required to brake the gate effectively
On the Danfoss VLT 2800
Press “quick menu” and “plus” at the same time
Press “+” and go to parameter #132
Press “change data”
Use “+” key to change current value in % of motor run current.
Press “change data” within 30 seconds to save
Press “Quick Menu” to escape
The drive gate DC Hold programming is enabled by default.
Firstly change the drive into Gate Forward & Reverse mode, change the data value in “005” to
data value “2” and save. This will need to be changed back to “5” upon completion of
changes.
Press “quick menu” and “plus” at the same time
Press “+” and go to parameter #132
Press “change data”
Use “+” key to change current value in % of motor run current.
Press “change data” within 30 seconds to save
Press “Quick Menu” to escape
Try the gate, you should hear the whining sound at the motor as it locks the position after
stopping on all forward and reverse actions. This sound will last for 3 seconds and then
release.
Spike Arrestor
A 15 Ka spike arrestor is wired into the incoming phase circuit; if this fails the audible within
this unit will sound to alert the operator that the arrestor needs replacement. The gate will
continue to work in this situation but will not have the same surge protection.
SAMWHA Electronic Over Current Relay
The two EOCR’s protect the drive motors, in normal mode the green LED is lit, in alarm mode
the red LED lights. The Alarm sounder in the controller will sound reset by pressing the reset.
The following are the EOCR standard settings;
Current
2.3 Amp
Motor FLA in Delta Configuration
Operating Time
10 Seconds
Overload Time before tripping
Delay Time
0 Seconds
Delay Time before relay can be reset
ASKARI Sounder
This 24VDC sounder has two different tones; the constant pulsed tone is for an Alarm
Situation and the siren tone for gate travelling forward or down. The unit has a volume control
on the top of the sounder as viewed from the front of the control box. Test the sounder alarm
mode by holding in the Stop Button on the control box lid for more than ten seconds.
Trouble Shooting
Common Error Messages.
WARNING/ALARM 4 Phase fault (MAIN PHASE FAULT). 3 phase gates only
A phase is missing on the supply side or the mains voltage imbalance is too high.
This message can also appear if there is a fault in the input rectifier on the frequency
converter.

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Cause/Remedy: Check to make sure all 3 Phases are ok to the drive, if these are ok check
other 3 Phase equipment in the Dairy. E.g. to make sure your power supply is ok to the
Dairy. Turn off the gate completely for 40 sec then back on, “RESET” and then “START” may
need to be pressed on the control panel on the Danfoss Drive.
WARNING 6 Voltage warning low (DC LINK VOLTAGE LOW).
The intermediate circuit voltage (DC) is below the under voltage limit of the control system.
Cause/Remedy: The incoming voltage to the gate is too low for it to operate.
E.g. there could be a fault with the power entering the drive. Check incoming supply and
cables.
The voltage will need to be returned to normal for the gate to operate
WARNING/ALARM 9 Inverter Overload (INVERTER TIME).
The electronic, thermal inverter protection reports that the frequency converter is about to cut
out because of an overload (too high current for too long). The counter for electronic, thermal
inverter protection gives a warning at 98% and trips at 100%, while giving an alarm. The
frequency converter cannot be reset until the counter is below 90%.
The fault is that the frequency converter is overloaded by more than 100% for too long.
Cause/Remedy: check motors for faults dry bearings or stiff gear boxes and check motor
data in the drive and perform an automatic motor adaption in the lift motor. Turn off the gate
completely for 40 sec then back on, “RESET” and then “START” may need to be pressed on
the control panel on the Danfoss Drive.
WARNING/ALARM 13 Over current (OVERCURRENT).
The inverter peak current limit (approx. 200% of the rated current) has been exceeded. The
warning will last approx 1 – 2 seconds, following which the frequency converter will trip, while
giving an alarm. Turn off the frequency converter and check whether the motor shaft can be
turned and whether the motor size matches the frequency converter. If extended mechanical
brake control is selected, trip can be reset externally.
Cause/Remedy: check motors for faults dry bearings or stiff gear boxes and check motor
data in the drive and perform an automatic motor adaption in the lift motor. Turn off the gate
completely for 40 sec then back on, “RESET” and then “START” may need to be pressed on
the control panel on the Danfoss Drive.
ALARM 14 Earth fault (EARTH FAULT).
There is a discharge from the output phases to earth, either in the cable between the
frequency converter and the motors or in the motors them self..
Cause/Remedy: Either the motor or the cable to the motor has a short to earth in it.
An Electrician will have to check this.
Turn off the Gate completely for 40 sec then back on, “RESET” and then “START” may need
to be pressed on the control panel on the Danfoss Drive.
ALARM 16 Short-circuit (CURR.SHORT CIRCUIT):
There is a short circuit on the drive this could be in the cables to motors, motor terminals,
windings or drive/lift relay.
Cause/Remedy: Either the motor or the cable to the motor has a short to earth in it.
An Electrician will have to check this.
Disconnect the drive at the motor output terminals and turn the gate back on to prove the
controller is OK.
Turn off the gate completely for 40 sec then back on, “RESET” and then “START” may need
to be pressed on the control panel on the Danfoss Drive
RUNNING FIRST TIME FAULTS Drive won’t start.
Drive in local stop after performing ama.

Copyright June 2014 – Steve Corkill
This manual subject to copyright and not to be copied without the express permission of Corkill Systems Limited
CSLRHLG-MANUAL-2014.DOC Page 13 17 April 2014
Cause/Remedy: After doing an ama on the lift motor you will need to reset the drive press
“RESET” and then “START” on the control panel on the Danfoss
RUNNING FIRST TIME FAULTS Siren sounds when turning on gate.
Break in Stop circuit, fault in supply cable or overloads tripped.
Cause/Remedy: check stop circuit on gate for faults (input #00 on the plc should be lit) Cable
running up the yard for breaks and check and reset overloads if necessary.
RUNNING FIRST TIME FAULTS Gate won’t go in direction X.
Limit switches faulty or not set.
Cause/Remedy: check the limit switches and adjust as necessary
RUNNING FIRST TIME FAULTS Gate operates in forward/reverse but stalls when in lift
mode.
The ama is not preformed or motor data is not set correctly in drive.
Cause/Remedy: Check motor parameters in the drive, perform an ama on the lift motor and
check gear box is free.
RUNNING FIRST TIME FAULTS Gate fails to work in cycle, sync or pulse.
The pots are set incorrectly.
Cause/Remedy: Check pots and adjust as necessary set to 1oc position and fine tune from
there.
RUNNING FIRST TIME FAULTS Gate travels in wrong direction when I press button X or one
of the drive motors goes in the wrong direction.
Motor or motor phases are inverted.
Cause/Remedy: invert motor phases of motor at the gate controller box for the affected
motors
Manufacture Details
Model No.
Serial No.
Danfoss Controller
VLT28
Omron PLC
CPM1A-20CDR-A-V1
PLC Program Options
R-
Danfoss Program
RHLG2006.VLT
Order Name
Manufacture Date
/ /
Manufactured by;
Corkill Systems Limited, 5 Tasman Street, PO Box 16, Opunake, New Zealand.
Phone (ISD 0064) 06 761 7531, fax [phone] or email: [e-mail]
All equipment contained within the Controller is Y2K Compliant and is manufactured to Telarc
Q-Base Quality Assurance Standards.
All equipment contained within the control enclosure is guaranteed 12 months from the date
of manufacture provided that the controller has been correctly installed by a registered
electrician and that all measures have been taken to prevent moisture ingression into the
enclosure. Damage from lightning or High Voltage surges are not covered by the warranty.
HELP!

Copyright June 2014 – Steve Corkill
This manual subject to copyright and not to be copied without the express permission of Corkill Systems Limited
CSLRHLG-MANUAL-2014.DOC Page 14 17 April 2014
If all else fails phone [phone] and state that you have a CSL Gate
problem, we will be pleased to assist.

Copyright June 2014 – Steve Corkill
This manual subject to copyright and not to be copied without the express permission of Corkill Systems Limited
CSLRHLG-MANUAL-2014.DOC Page 15 17 April 2014
Corkill Systems Limited - TERMS AND CONDITIONS OF SALE
GENERAL
All quotations, orders and contracts for the sale or supply of goods or services by Corkill Systems Limited shall unless, otherwise agreed in writing, be
subject to the following terms and conditions:
1. ORDERS All orders are made and accepted on the terms and conditions here stated. Order cancellations are subject to terms agreed as at time
of cancellation.
2. PRICES Prices quoted remain firm for 30 days but beyond that time prices may be adjusted.
3. DELIVERY
Delivery dates given by Corkill Systems Limited are approximate and rely on prompt receipt of all necessary information regarding the
order. Corkill Systems Limited will use their best effort to meet the estimated date but will not be held liable for any delay due to
circumstances arising in the industry generally or within Corkill Systems Limited work due to delay in receipt of supplies from sub-
contractor or any other circumstances beyond Corkill Systems Limited control. No liability will be taken for any late deliveries unless
delivery date has been guaranteed by Corkill Systems Limited in writing. Otherwise Corkill Systems Limited will use its best endeavour to
meet delivery dates.
4. DELIVERY CHARGES
Unless otherwise agreed in writing or at the discretion of Corkill Systems Limited, all freight will be charged to the Purchaser’s account.
5. RETURN OF GOODS
No goods may be returned without prior written approval of Corkill Systems Limited and may be subject to a restocking fee.
Approval will be contemplated by Corkill Systems Limited only in circumstances where:
5.1 Advice of any proposed return is given within 30 days following the date of the invoice.
5.2 Transportation and other costs for return are prepaid by the Purchaser
5.3 Goods to be accompanied by a copy of Corkill Systems Limited Packing Slip or Invoice
5.4 Goods to be accompanied by a written explanation of reasons for return.
5.5 Corkill Systems Limited may charge for handling, inspection, disassembly or reconditioning stock items.
5.6 Units manufactured, modified or imported as special or unique units will only be accepted for credit
less the cost of converting the unit back to a standard saleable unit.
6. TERMS OF PAYMENT
All goods shall be paid for on the 20th day of the month following delivery. Corkill Systems Limited may at any time require full or part
payment in advance of delivery and the purchaser shall not be entitled to any damages or compensation arising from such requirement.
Goods on time payment shall be subject to the conditions on the Time Payment contract in addition to the terms contained within this
document.
7. PRODUCT SAFETY
Corkill Systems Limited products are supplied and manufactured to high standards but no electrical equipment is failsafe within itself.
When risk to person or property may be involved a fail-safe device should be an integral part of the equipment, the entire responsibility for
which rests with the Purchaser.
8. OWNERSHIP OF GOODS
The goods shall remain the property of Corkill Systems Limited until they have been fully paid for. Risk shall pass to the purchaser on
delivery. The purchaser will insure the goods. The purchaser acknowledges that it is in possession as agent and bailee for Corkill
Systems Limited and owes a fiduciary duty to Corkill Systems Limited until such time as legal and equitable title shall transfer. The
purchaser’s right to possession of unpaid goods shall terminate on demand by Corkill Systems Limited, which may enter or authorise an
agent to enter the purchaser’s premises to recover the goods.
9. PRODUCT WARRANTY
Provided that the product has been subjected to normal and proper use only, all new products supplied by the company are warranted to
be free from defects in materials and workmanship from the date of shipment to the Purchaser either for one year or the Manufacturers
warranty term subject to the following conditions:
10.1 All electrical equipment to be installed and commissioned by qualified trade-persons.
10.2 Adequate measures to be taken against moisture and/or mechanical damage.
10.3 Recommended cabling procedures and/or circuitry protection must be provided.
10.4 Suitable overload protection be provided and installed where required.
10.5 All faulty components to be returned to Corkill Systems Limited before a credit can be made.
In the event of equipment failure, all faulty components will be repaired or replaced free of charge, consequential loss/equipment damage
and/or labour and/or travelling will not be subsidised. Any unauthorised dismantling, repair or modification voids this warranty.
10. LIABILITY UNDER WARRANTY
Corkill Systems Limited liability under this warranty or any other warranty whether express or implied in law or fact shall be limited to the
repair or replacement of defective material and workmanship and in no event shall Corkill Systems Limited be liable for consequential or
indirect damages.
11. GOVERNING LAW This agreement shall be construed according to the laws of New Zealand.

Copyright June 2014 – Steve Corkill
This manual subject to copyright and not to be copied without the express permission of Corkill Systems Limited
CSLRHLG-MANUAL-2014.DOC Page 16 17 April 2014
N P G L M R D M L D M 3 3 4 5 6 7 8 U D F R S R N
DANFOSS
VLT2807
SINGLE PHASE
MOTORN P E
OVERLOAD
RELAY EOCR-SS
0.5-6.0 A
FINDER 56.34
24V DC RELAY
96.74 BASE
OVERLOAD
RELAY EOCR-SS
0.5-6.0 A
OMRON
CP1L-L20DR-A
PLC
DMS
P15
PDL
F U
S
E H O L D E R
F 46 . 61
24VDC
D E
CORKILL SYSTEMS LTD
2 King St, PO Box 16
OPUNAKE, TARANAKI. NEW ZEALAND
Ph [phone] Fax [phone]
LAYOUT DIGRAM FOR
CSL HIGH LIFT GATE
2014
17 April 2014
CSLRHLG-LAYOUT-2014.pub
B C3 A
F U
S
E H O L D E R
230/24/25VA
TRANSFORMER
24VAC
230VAC

Copyright June 2014 – Steve Corkill
This manual subject to copyright and not to be copied without the express permission of Corkill Systems Limited
CSLRHLG-MANUAL-2014.DOC Page 17 17 April 2014
CORKILL SYSTEMS LTD
5 Tasman St, PO Box 16
OPUNAKE, TARANAKI. NEW ZEALAND
Ph [phone] Fax [phone]
CSL LIFT GATE CONTROL
24Volts DC CIRCUIT DIAGRAM
2014 Model
WH/GR-#8
3 4 5 6 7 8 UP DN FWD REV RED BU BK
MULTICORE CABLE
1.5mm
3
COMMONS MULTICORE CABLE NUMBERS MICROSWITCHES SIREN OUTPUT
TOSUPPLY
TERMINALS
1 & 2
PLUS EARTH BAR
MAIN
JUNCTION
BOX
MAIN
SUPPLY
230V
SIREN
PUSH BUTTON STATION
MAIN CONTROL PANEL
CONNECTIONS
1. MULTICORECABLE:
(a) Connect corresponding numbers in the Control Box to theMulti -core cables #3 through to #8.
(b) Connect corresponding numbers in the Main Junction Box to the Multicore cables #3 through to #8.
2. Push Button Station, connect in the Main Junction Box as per the following;
3. Microswitches, all switches arenormally closed and open when activated, all switches share Common Terminal #3 at the Main Control Panel. The Gate Lift
Microswitch only requires three cores (shared Common) and Forward and Reverse switches require two cores.
4. Siren, this is hard wired in the Main Control Panel. The sounder has two tones, the first sound (Red Wire) is for normal Forward operation,
the second tone (Blue wire) will be activated if an Alarm condition is activated in the Main Control Panel.
Reset by turning theIsolator “OFF” for 40 seconds and then back on after rectifying fault condition.
Multicore #3 to White/Orange (Common) Multicore #4 to Orange/White (Stop Button) Multicore #5 to Blue/White (Up Button)
Multicore #6 to White/Blue (Down Button) Multicore #7 to Green/White (Forward Button) Multicore #8 to White Green (Reverse Button)
P-RED #2 N-BLK-#1
WH/OR-#3 OR/WH-#4
BU/WH-#5
WH/BU-#6
GR/WH-#7
EARTH
S
T
O
P
U
PD O
W
N
F
O
R
W
A
R
D
R
E
V
E
R
S
E
F
W
D
W
A
S
H
REVERSE
M S/W
FWD
M S/W
DOWN
M S/W
UP
M S/W
TO TERMINAL 3
MAIN
JUNCTION
BOX
CORE #9
CORE #10
PRESSURE (NO)
M S/W
BA C3
LOCATED ON GATE
C
O
M
TOP
TERMINALS
17 April 2014CSLRHLG-WIRE- 24V-2014.PUB
S
Y
N
C
S
W
P
U
L
L
S
W
USE 12 CORE MULTICORE
TO USE THESE OPTIONS
MULTICORE
CABLE
1.5mm
SIMLPLE CONNECTION WITH 8 CORE
MULTICORE
C
Y
C
L
E
S
Y
N
C
/
P
U
L
S
E
R
E
V
W
A
S
H

Copyright June 2014 – Steve Corkill
This manual subject to copyright and not to be copied without the express permission of Corkill Systems Limited
CSLRHLG-MANUAL-2014.DOC Page 18 17 April 2014
CT
CT
CT
CT
P
N
E
G
L
M
L
D
M
D
R
M
1 Amp
Fuse
K&N
A290 SWITCH
T#1 & T#2
FINDER
56.34
24VDC
(Omron LY4
equivalent)
CONNECTIONS KEY
P = Phase/Live
N = Neutral
E = Earth (from Earth bar)
GLM = Gate Lift Motor (Blue wires)
LDM = Left Drive Motor (Yellow wires)
RDM = Right Drive Motor (Orange
wires)
CONNECTIONS
1. Provide a 2.5mm Single Phase supply to the Junction Box position.
2. Fuse this supply to 16Amps using either Motor Rated HRC fuses or a Circuit-breaker.
3. Connect supply to Red, Black and Green DIN connectors in the junction box provided.
4. MULTICORECABLE:
(a) Connect wire #1between the J/Box Phase (Red) connector and P#1 in the Control Box
(b) Connect wire #2 between the J/Box Neutral (Black) connector and N#2 in the Control Box
(c) Connect wire #3 between the J/Box Earth (Green) connector and the Earth stud in theControl Box
5. MOTORS:
Wire all motors using theCBS cable provided connecting both the Earth conductor and the screen to the Earth bar,
and the motor Earth terminal. Connect motor phases to the corresponding terminals according to the KEYon this
diagram (eg LGM, LDM, and RDM).
ALL MOTORS TO BE WIREDIN DELTA eg NOT STAR eg
NOTE MOTOR BRIDGE POSITIONS
NOTE:
This diagram re lates only to the 230V
high voltage connections of the
control system, low voltage inputs and
outputs are on the LV Diagram.
CORKILL SYSTEMS LTD
5 Tasman St, PO Box 16
OPUNAKE, TARANAKI. NEW ZEALAND
Ph [phone] Fax [phone]
CSL HIGH LIFT GATE CONTROL
230Volts CIRCUIT DIAGRAM
2012 Model
17 April 2014
CSLRHLG-WIRE-230V-2014.PUB

Copyright June 2014 – Steve Corkill
This manual subject to copyright and not to be copied without the express permission of Corkill Systems Limited
CSLRHLG-MANUAL-2014.DOC Page 19 17 April 2014
CORKILL SYSTEMS LTD
5 Tasman St, PO Box 16
OPUNAKE, TARANAKI. NEW ZEALAND
Ph [phone] Fax [phone]
CIRCUIT DIAGRAM FOR
CLS BACKING GATE CONTROLLER
2014 MODEL
4 September 2013COPYRIGHT JUNE 2001. STEVE CORKILL
CSL GATE WIRE-2013.pub
GATE MOTOR
TERMINALS
K&N A292
DOOR SWITCH
3 4 5 6 7 8
UP
DOWN
FWD
REV
3
09
0703
10080402
01
TO PLC INPUTS
RS N
D EA CB
PULL SWITCH
PRESSURE
SYNC
3
05 06 11
TO PLC INPUTS
DANFOSS DRIVE
TERMINALS
12 18 19 20 27 29 33
13AUX
DANFOSS VLT2815 3 O
DRIVE UNIT
TO PLC OUTPUTS
07
06
05
04
03
COM 3
L1 L2 COM 00 01 02 03 04 05 06 07 08 09 10
- + COM 00 COM1 01 COM2 02 03 COM3 04 05 06 07
11
OMRON PLC
CPM1A-20CDR-A-V1
PLC INPUTS
PLC OUTPUTS
COIL
A1 A2 N C 2
N O 3
C O M
(WASH)
FINDER
RELAY
46.61-24DC
SUPPLY SIREN
TO DANFOSS
MAINS PLUG
TO GATE LIFT MOTOR
TERMINALS
PLC INPUT 00
PLC OUTPUT 07
DOOR STOP P/B
TERMINAL
STRIP 3
SURGE
PROTECTION
DANFOSS
MOTOR
PLUG
DANFOSS
POWER
PLUG
TO CHANGEOVER
RELAY
COM 3
00 01
PLC +
19 27 29
WASH
RELAY A1
18
TO DANFOSS DRIVE
TERMINALS
TO CHANGEOVER
RELAY A1
TO DANFOSS
AUX 3
5 6 7 C8 A B U D F R
TO TERMINAL STRIP
MG L ML D MR D
2N 1 3
EOCR O/L 98
FUSE
LEFT DRIVE
MOTOR
RIGHT DRIVE
MOTOR
FUSE
TO PLC OUTPUTS
PUSH BUTTON
INPUTS
LIMIT
SWITCHES
THROUGH OVERLOADS
TO LIFT DRIVE RELAY
WHITE
12
TO SIREN
SN
R
TO SURGE DIVERTER
TO MAINS
SWITCH
33
TO DANFOSS
MAINS
230/24/25VA
TRANSFORMER
24VAC
230VAC
WASH SOLENIOD
(CHANGEOVER RELAY)
FINDER RELAY
56.34-24VDC
A2 A1
12 11 10 9
N O N C
4 3 12 8 7 6 5
3
4
5
6
E
PLC OUTPUT 2
TO DANFOSS
MOTOR PLUG
TO MAINS
SWITCH
TO SURGE DIVERTER
NEUTRAL
SINGLE
PHASE
OPTION
K&N A290
DOOR SWITCH
TO DANFOSS
MAINS PLUG
N 1
SINGLE
PHASE
OPTION
OVERLOAD
RELAY
L1 L2 95 96 98
TO DANFOSS
AUX 1
43
OVERLOAD
RELAY
L1 L2 95 96 98
1 2
DOOR STOP
PUSH BUTTON
WHITE
TO OVERLOAD

Copyright June 2014 – Steve Corkill
This manual subject to copyright and not to be copied without the express permission of Corkill Systems Limited
CSLRHLG-MANUAL-2014.DOC Page 20 17 April 2014
CORKILL SYSTEMS LTD
5 Tasman St, PO Box 16
OPUNAKE, TARANAKI. NEW ZEALAND
Ph [phone] Fax [phone]
CIRCUIT DIAGRAM FOR
CSL HIGH LIFT GATE CP1L
MODEL 2014
17 April 2014CSLRHLG-4X4-WIRE-DOOR- 2014.pub
TERMINAL
BLOCK
DOOR LOOM WIRING LAYOUT
L1 L2 L3
VLT2807 1Phase
DANFOSS
DRIVE
K&N
A290 NZ0011 SWITCH
R E V Q R E V
F O R Q F O R
D O W N
U P
3 3 4 5 6 7 8
OVER LOAD
WIRE 1 TO 98 ON
OVERLOAD &
TO STOP P/B ON
DOOR
3 87654
3
S T O P
1
U D F R
MULTI CORE CABLE
OVER LOAD
F
W D
/
W
A
S
H
S
Y N C O R
P U L
S
E
C Y C L E
R E V
/
W
A
S
H
WIRE FOR DIFFERENT OPTIONS
SEE OPTIONAL PROGRAM/ OPTIONS
PAGE 2
. . . .
H B
S
Y N C O R