GDS GDS 450 W Manual

Installation and Maintenance Manual
Sliding Gate Operators
Inbuilt Models: GDS 450, 630 W Range
Made in Australia from Australian & quality imported components
A.B.N. 62 059 806 405
October 2013
N14870

2
Abbreviated Installation Instructions
(For those who don't have time!)
S l i d i n g G a t e O p e r at o r s
GDS 450, 630 W Range
PLEASE NOTE – THE LIMIT SWITCHES WITH THIS RANGE OF OPERATORS ARE ONLY USED
TO CHANGE FROM FAST SPEED TO SLOW SPEED, THE OPERATOR IS DESIGNED TO DRIVE
THE GATE ONTO THE MECHANICAL STOPS WHERE THEN THE MOTOR WILL TURN OFF
Place operator in correct position (Pinion wheel to be parallel to
the gate and stepped out to allow for width of rack once it is
mounted onto the gate frame). Mark out fixings and fix operator
to the concrete pad.
Fix rack to the gate frame keeping 1mm-2mm clearance between the
rack teeth and Pinion wheel
Once the rack is fixed move the gate and sight the rack moving
over the pinion wheel, check that most of the pinion wheel
meshes with the rack. Make sure rack runs freely over the
pinion wheel, any tights spots should be corrected by adjusting
the rack height. Check the operator is firmly bolted down to
the concrete pad.
Ensure adequate engineered stops are installed on the gate for the
fully closed and fully open positions.
Connect required P.E Beams. Manually move the gate taking
note of at what point the open and close slow speed switches
activate, adjust the slow speed switch cams to actuate prior to
gate end stop positions. (a slow speed area of around .5m is a
good starting point). The operator has been set to open to the
left as you look at it on the inside facing the gate, with the top
cam switch being for the open slow speed and the bottom cam
switch being for the close slow speed. Connect Power supply.
Turn on Power.

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To commission the gate, move the gate approximately half
way and tighten the knurled wheel (Clockwise) engaging the
clutch assembly enough that it will drive the gate but will slip
if it accidentally hits its mechanical stop hard during set up.
Make sure at end of set up that the clutch is tightened up
firm.
Press the opening button located under the dip switches to
begin opening cycle.
Ensure the direction the gate travels is in accordance with
the opening and closing status LED’s, if not reverse any
two of the motor wires at the inverter terminals. Then
adjust the slow speed switch cams around ensuring the
open cam switch activates in the open direction, and so too
the close cam for the close direction well before the gate
reaches it`s full open and closed positions.
Inverter settings can be adjusted if needed via the keypad i.e.
Opening speed, closing speed and ramp times. Automation
settings operating modes are able to be adjusted via the CB6
board, refer to manual for further instructions.
Once inverter settings are appropriately set, proceed to make
finer adjustments to the slow speed switches
Making sure the gate travels into its open and closed
mechanical stops at the slow speed and changes to its slow
speed at a comfortable distance before it reaches the final stop
positions. A larger gate will need a larger slow down area.
Don`t forget to set run motor run travel timing via the
run/set switch as described in commissioning.

4
CONTENTS
Section numbers page numbers
Abbreviated Installation Instructions 2-3
1 Safety Precautions 5
2 Product description and operation 6
3 Installation details 6-13
Mechanical Installation
Wiring requirements
Plan view of operator installation for conduit entry points
CB6 Control Board
CB6 inputs, outputs and settings
Variable Speed Drive Unit
Commissioning
Inverter parameter list
Using inverter monitoring function parameters for fault finding
4 Schematic wiring diagram of controls 14
5 Manual release operation 15
6 Maintenance schedule 16
7 Warranty 17

5
1. S AFETY P RECAUTIONS
WARNING! FAILURE TO FOLLOW THESE SAFETY PRECAUTIONS AND INSTALLATION
INSTRUCTIONS COULD RESULT IN INJURY OR DEATH AND / OR DAMAGE TO PROPERTY AND
EQUIPMENT .
•Appropriately licensed and competent personnel only should install the automation equipment.
•The operators are designed specifically to open and close sliding gates or doors and should not be used for any
other purpose.
•Before commencing installation, read through this installation manual.
•Check that the operator and controls are in new condition and have not been damaged in transit.
•Check the gate or door and it`s associated support posts and walls to protect against shearing, compression and
other various traps which could cause serious injury or death. Take into consideration the general installation and
surrounding environment.
•Check the gateposts or mounting structure has the necessary strength and rigidity to support the operator and the
load of the opening and closing gate motion.
CAUTION!
Always incorporate the appropriate Photo Electric Cells, Induction Loops and any other safety devices to
protect both equipment and personnel. Extra caution should be employed when using operator in auto
close mode.
•Display any necessary signs to indicate any danger areas and automatic operation of the gate or door.
•The operators are not designed to be used in any hazardous areas or areas subject to flooding etc.
•All electrical connections and wiring must be performed with AS/NZS 3000-2007 as the guidelines. (Or its
counterpart for other countries outside of Australia and New Zealand)
WARNING! ELECTRICITY CAN KILL
•The manufacturer of the automation equipment is not responsible for the damage which may be caused to either
the operator, gate or door and any other person or equipment when: -
oWrong or poor installation practices were performed.
oNo or inadequate safety devices were used.
oEither the surrounding structure or the gate or door strength and rigidity was not sufficient for the task in
hand.
oInefficient locking devices were employed.
oPoor maintenance on the equipment.
oAny other circumstances beyond the manufacturers control.
• Isolate power before attempting any maintenance, qualified personnel only to carry out maintenance
• Only original spare parts are to be used should there be a requirement for them.
• Keep loose clothing and hands clear of the gate whilst in operation or potentially able to be operated.
• The installer should provide all information concerning the use of the automation equipment as well as
instructions regarding the manual override and maintenance procedures to the users of the system.

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2. P RODUCT D ESCRIPTION AND O PERATION .
This operator has been developed in order to make installation, commissioning and gate operation as simple
and hassle free as possible without detracting from the quality that has always been the trademark of the GDS range of
operators.
Apart from the upgrade of inverter control to the Prostar unit and cabinet style enclosure with the option of
internal or external fixing points, the traditional limit switch type of system which initiates the ramp down time period
then stopping of the gate at the end has been changed to suit a wider range of gate sizes without having to change
chain drive sprocket sizes or limit gear ratios to match.
The chain driven cam switches are connected to initiate a second slow or homing speed which then at that
slow speed, the gate is allowed to drive into the post/mechanical stop smoothly, then after a programmed time delay,
the inverter detects a rise in current and signals the CB-6 board to stop that cycle of operation. With this method of
control, apart from the advantages over traditional limits described above, there is a more gentle or controlled stop
allowing easier aligning of electric gate contact switches, electric locks etc, and with no physical limit switches,
adjustment of the gates final stopping position will never need adjusting as long as the mechanical gate stops used are
adequate for the gate. Also, as long as the gate rack at operator drive pinion are in good order and adjusted correctly
with normal recommended maintenance, the slow down area shouldn’t need adjusting. Even if the rack does get out
of adjustment with the drive pinion, there will be a certain amount of room for error through the adequate adjustment
of the slow down area before the gate reaches the mechanical stop. Even if the gate ends up hitting the mechanical
stop at full speed either the inverter will detect the sudden current rise and cut power to the motor in turn displaying a
fault code on its display, and the clutch will slip.
The Prostar inverter has an advanced function parameter list with a detailed list of monitoring display
functions for both the operation of the inverter and status of the inputs to the inverter also with logging of the last 3
faults and recording of the operating conditions of the inverter at the first fault, taking some of the guess work out of
fault finding on site.
3. I NSTALLATION D ETAILS
Mechanical installation
•Ensure gate rolls easily and has been installed in a manner where there is no excessive friction or binding
occurring.
•IMPORTANT ensure there are gate stops firmly installed in the fully open and closed positions. These stops
need to be engineered and installed such that they will be strong enough to stop the gate should the limits fail at
any time.
•A concrete base approximately 750mm long x 300 wide x 300mm deep should be laid where the gate operator is to
be located.
•Position operator in approximate mounting location.
•Use a section of rack to locate the operator the correct distance away from the gate rail (finer adjustment can be
made after).
•Dynabolt or chemical anchor the bottom mounting plate to the concrete mounting pad using 12 x 100mm fixings in
either the inside or outside slotted mounting holes.
•Unscrew anticlockwise the manual disconnect knurled knob so the drive gear free wheels.
•Fix the rack to the gate rail ensuring there is approximately 1mm - 2mm gap between the meshing of the teeth of
the rack and the drive gear (no more). Move the gate by hand from one end to the other while checking that the
rack is meshing correctly with the drive gear on the operator. Check also that the rack is centred around the middle
of the teeth on the drive cog – tighten the mounting plate nuts.

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W IRING R EQUIREMENTS
• 240v 10A non earth leakage protected power supply where operator is mounted.
• Extra low voltage cables from operator to field equipment such as photo cells, access control etc, should be
shielded type cable if cable length is over 8m and especially if wirings runs directly next to medium or high voltage
cabling such as mains power.
Electrical Cabling
• A suitably rated Isolator and 240v power supply should be available near to where the gate operator is to be
mounted. The following diagrams will provide measurements for the positioning of conduits and the appropriate
position for mounting the operator whether a GDS 450 W or a GDS 630 W.
Electrical Connections
•Connect a non earth leakage protected 10A 240v supply to Din Rail terminals labelled A & N, Connect earth to the
earth Din Rail terminal.
•Conduits for power & control need to preferably come up through the base plate 'knockout'.
Connections to Control Board
•All control wiring associated with the inverter and low speed switching has been installed.
•Any external field wiring for photo cells, access control, locking etc will have to be connected to the appropriate
inputs and outputs on CB-6 board.
P LAN VIEW OF TYPICAL INSTALLATION AND OPERATOR DIMENSIONS

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CONTROL BOARD LAYOUT FOR INVERTER CONTROLS
1.
Mode Selection and Adjustment 17. Electric Lock Control Terminals
2.
Protection Fuse 18. Terminals for 24vAC Supply for
3.
Inverter Input Terminals Control Logic
4.
Motor 1 Drive Output Terminals for Inverter 19. Plug In Receiver Antenna Terminals
5.
Motor 2 Drive Output Terminals for Inverter With Optional Shield
6.
Motor 1 Limit Switch Inputs 20. Connector for Plug-In Receiver
7.
Motor 2 Limit Switch Inputs (not shown)
8.
Terminals for Isolated 24vAC Supply 21. Firmware Version Label
for Limit Switch and Control Inputs
22.
Light Control Relay Interface
9.
Pedestrian Access Control Input Connector
10.
Open/Stop/Close Control Input 23. Input Status L.E.Ds.
11.
Close Control Input 24. Stop Input Jumper
12.
Stop Control Input 25. Open Input Jumper
13.
Open Control Input 26. PE Beam Input Jumper
14.
Photoelectric Safety Beam Input 27. M2 Close Limit Jumper
15.
Common Terminal for Inputs [9] 28. M2 Open Limit Jumper
Thru [14].
29.
M1 Close Limit Jumper
16.
Control Input Harness Connector
30. M1 Open Limit Jumper

9
Control Inputs
The P.E, OPN and STP inputs require a normally closed switch contact and therefore should be shorted to the COM
terminal if not used. This is done via bridging links already on the circuit board (bottom left corner) The CLS, OSC
and PED inputs require a normally open switch contact and therefore should be left unconnected if not used. All the
switch inputs of this control board including the limit switch inputs require a switch contact only. Do not connect any
switches which provide a voltage to the control board as this will damage the control board. If the desired inputs are
12/24v or has long wiring associated with it use an IM-1 module to isolate it from the control board’s input. The IM-1
is available from the manufacturer.
Powering Accessories
Accessories which require a 24v AC supply can be powered from the transformer output used to power the control
board via the isolated 24v AC supply which is connected to the DIN rail terminals as labelled. However, the
transformer’s current capacity must be checked to allow for the extra power required by the accessories. Never use the
supply connected to the 24v AC supply control board terminals to power any accessory as this can interfere with the
control boards operation. (Blue Wires)
Locks & Lights
Use the lock output terminals on the din rail to switch the 12 volts to an electric lock (if fitted). The load switched by
the lock output terminals must not exceed 30V A.C / D.C @ 5Amps. If an electromagnetic lock is used, change one
wire on the control board lock output to the normally closed output. Use the light relay module (if fitted) to switch the
applied voltage to a light. The load switched by the light relay module must not exceed 240V A.C / 30V D.C @ 10
Amps.
Mode Selection
Using the mode selection dip-switches select the desired operating modes. Note the times associated with the
parameters marked with an * can be changed. The auto-close times can be changed using the procedure in the
following section. See the instruction manual for details on how to change the other parameters.
See the detailed instruction manual for details on how to change the other parameters.
Position 1 SYNCHRONISING DELAY
OFF - No delay
ON - Motor 1 starts to open 2 seconds* before Motor 2 and Motor 2 starts to close 2 seconds* before Motor 1.
Position 2 PULSE LOCK OUTPUT
OFF - Lock output is activated for the entire motor drive cycle.
ON - Lock output pulses for 0.3 seconds* at the start of each drive cycle.
Position 3 LIGHT OUTPUTS WARNING
OFF - Optional light module controls a light with timer which turns light off after 60seconds*.
ON - Optional light module controls a warning light which activates whenever motors are on.
Position 4 SWIPE MODE (OSC INPUT)
OFF - OSC input terminal has standard Open, Close, Stop action.
ON - OSC input terminal will only open the door/gate. The input also resets the P.E triggered
auto-close mode so that the P.E input will need to be triggered again before a P.E auto-
close cycle will be initiated.

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Position 5 M 2 OUTPUTS STATUS
OFF - The M2 output controls second motor
ON - The M2 output controls status lights
Position 6 P.E STOPS CLOSE CYCLE
OFF - Activating the P.E input while motors are closing causes the motors to reverse.
ON - Activating the P.E input while motors are closing causes the motors to stop but not reverse.
Position 7 P.E STOPS OPEN CYCLE
OFF - Activating the P.E input while motors are opening is ignored by the controller.
ON - Activating the P.E input while motors are opening causes the motors to stop.
Position 8 P.E TRIGGERED AUTO-CLS
OFF - Not selected
ON - Selects the P.E triggered auto-close mode which causes the motors to auto-close if
the P.E input is activated then released. (Auto-close delay time is 0 seconds*)
Position 9 PEDESTRIAN AUTO-CLS
OFF - No pedestrian access auto-close
ON - Selects auto-close in the pedestrian access mode. (Auto-close delay time is 15
seconds*)
Position 10 STANDARD AUTO-CLS
OFF - Not selected
ON - Selects standard auto-close mode which will close the motors after fully opening.
(Auto-close delay time is 30 seconds*)
Setting Cycle Timers & Auto Close Times
The control board has pre-set cycle times which are used to set the maximum time the controller will drive the motors
in the open and closed directions. The pre-programmed time for the open and close cycle timer’s is 60 seconds. The
control board also has a pre-set pedestrian access time of 5 seconds which is intended to open the motor connected to
M1 output only part way. If these default times do not suit your needs simply use the procedure below to adjust them.
Note the same procedure can be used to adjust the auto-close times.
1. Place the slide switch into the “set” position
2. Adjust the timer’s value by pressing and holding the required push button for the desired time.
3. Repeat step 2 for the next timer (if desired).
4. Place the slide switch back into the “RUN” position.
5. Test operation.
Make sure that the slide switch is placed back into the “RUN” position before testing the new timer value.
As you can see the procedure used to set each timer’s value is the same only the push button used changes. Each push
button is clearly labelled underneath as to which timer’s value it sets. Note when setting the OPEN, CLOSE and
PEDESTRIAN cycle times the controller will drive the motors as if a “real” cycle is being executed. The difference
being that the motors will stop as soon as the button is released or the limit switches are reached. The OPN status LED
on the control board will flash at 1 second intervals to assist setting times. Note when setting the OPEN and CLOSE
cycle times when limit switches are used, release the push button a few seconds after the limit switch cuts motor
power. This allows for the motors to slow down over the life of the operators without the need to adjust again.

11
Commissioning
•Position the gate halfway and tighten clutch (knurled knob on gearbox) just firm enough to drive the gate but still
allowing it to slip if the slow down switches aren’t adjusted correctly and the gate hits the mechanical stops at full
speed.
•Power up board and with gate in the half way position, press transmitter or manual control switch so operator
drives gate.
•The first pulse will always open gate, green LED will flash (top right hand corner) if it does not, then reverse 2 of
the motor wires. The operator has been set up in the factory to open up to the left when looking at the gate
from the inside or secure side of the property, so in reversing the direction of the motor, the open and close
slow speed switch cams will have to be adjusted to match the new opening and closing directions.
•Check that the slow speed switches are set correctly for the direction the gate is travelling in and adjust cams so
gate will slow down when approaching the fully open and closed positions. Do not alter wiring connections.
•Once happy with the slow speed area settings tighten the clutch knurled knob very tight.
•Set open & closed travel times as explained earlier.
•Check that all safety devices work as designed and tested.
•Install cover using screws provided in the front and sides to hold cover firm.
Provide full details to the owner concerning the operation and relevant maintenance and disconnect details.
Variable speed drive unit
•The variable speed drive unit will, ramp up the speed of the operator and then ramp down prior to closing.
•It must be remembered that the limit switches are to be set in a position which initiates the slow speed area time,
therefore the limit switches need to operate much sooner than when there is no variable speed drive unit.
•The acceleration and deceleration times, open and close speed and slow speed area times have been set in the
factory for the normal installation but can be changed if necessary. Similarly, the speed that the gate operates at
has also been set but can be changed (up to approx 70Hz).
•The gate stop current trip margin can be changed if required on a larger gate.
Navigating through inverter menu
• From the main screen “0.00” press the PRG button twice to get to the parameter menu screen “P0.00”.
• Use >> button to select required digit on screen to change then scroll that digit up or down with the up/down ↕
button.
• Use up/down ↕buttons to get to the required parameter number, once number selected, press “SET” to enter into
required parameter, once in, use the up/down ↕
buttons again to change the number.
• Once parameter has been changed, the display will start flashing, while it`s flashing press set to enter the new
number. If that new entry has been accepted the display will stop flashing.
• Press SET again to change back to the parameter menu screen.
• Once finished with the changes, press PRG again return to main screen “0.00”.
• FACTORY SET PARAMETER LIST ON NEXT PAGE.

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Proflex PR600 Inverter parameter list for Wholesale Operator
Parameter list number Definition Setting
P0.01 Keypad up/down button
frequency control
1
P0.06 Upper limit frequency 70
P0.03 Opening speed 60-sliders
50-swings
P0.04 Running command via
terminals
1
P0.09 Max output voltage 230
P0.14 Acceleration time 5.0
P0.15 Deceleration time 2.5
P2.28 Closing speed 30
P4.00 Closing Speed
Input terminal DI1
1
P4.01 Opening slow speed jog
terminal DI2
9
P4.02 Closing slow speed jog
terminal D13
10
P4.09 Programmable relay output
Inverter overload alarm set
8
P4.13 Overload pre alarm
Checkout level percent
60
P4.14 Overload pre alarm
Delayed time
3.0
P2.19 Slow speed jog running
frequency
12
P2.20 Jog acceleration time 1.5
P2.21 Jog deceleration time 1.5

13
Using inverter monitoring parameters for monitoring and fault finding
• From the main screen “0.00” press the PRG button once to get to the parameter menu screen “D-00”.
• Use >> button to select required digit on screen to change then scroll that digit up or down with the up/down ↕
button.
• Use up/down ↕buttons to get to the required parameter number, once number selected, press “SET” to enter into
required parameter. The screen will display the information for that parameter number.
Selection of handy parameters to use: *full list shown inverter manual
D-19 to D-21 = Last 3 fault records *handy especially if the power has been turned off after a fault and you need to
Know what the fault code was.
D-15 to D-16 = Temperature reading *Check if suspected overheating of inverter.
Inverter components
D-14 = Inverter input terminal *Used to check that the inverter is receiving the correct signals from CB-6
Status Board. In this way you can determine if the existing fault is related to either
The CB-6 board or the inverter.
*Use diagram below to determine status of inverter inputs different
LED display segments represent each input.

14
4. S CHEMATIC W IRING D IAGRAM

15
6. M ANUAL R ELEASE I NSTRUCTIONS
Place key in door lock turn clockwise till released then pull open door.
Turn knurled knob anticlockwise approx. 1/2 a turn to release clutch.
Gate can now be opened by hand.
To re-engage the clutch move the gate by hand
into approx the half way position and turn the
the knurled knob clockwise until it is very tight.
If when turning the knurled knob clockwise and it
just spins, either try spinning it clockwise with a
bit more force to release it of the hexagonal
retaining nut or hold the nut with one hand and
turn the knurled knob clockwise with other hand

16
6. M AINTENANCE D ETAILS
WARNING!
Failure to maintain equipment may result in injury or death and/or damage to property and equipment
Recommended maintenance to be performed on the operator and gate are as follows:-
Operator performs over 150 cycles a day each month
Operator performs between 100-150 cycles a day every 2 month
Operator performs between 50-99 cycles a day every 4 months
Operator performs between 20-49 cycles a day every 6 months
Operator performs under 20 cycles a day every 12 months
Date: ..............................................................................................
Site Name:..........................................................................................................................................................
Site Address: ......................................................................................................................................................
Before commencing maintenance on the operator, isolate the electrical supply to ensure operator will not run
inadvertently.
Gate rolls freely when in manual..................................................................................... 
Gate wheels and guide rollers in good condition............................................................. 
Gate stops in good condition and not loose ..................................................................... 
Gate rack is tight & correct clearances between pinion wheel & rack............................ 
Gate track is not damaged................................................................................................ 
Gate operator mounting bolts right.................................................................................. 
No oil leaks from gearboxes ............................................................................................ 
Gearbox mounting bolts/nuts tight .................................................................................. 
Inside operator and control box clean.............................................................................. 
‘Baygon’ Surface Spray around operator and control box (not on electronics) .............. 
All electrical connections tight ........................................................................................ 
Limit Switches operate in appropriate positions/ chain oiled.......................................... 
External safety devices work effectively / cleaned.......................................................... 
Electromagnetic lock, if fitted, operates correctly and is clean....................................... 
Wash down of control box and cover (particularly near corrosive/ sea environments..... 
General operation i.e. speed, auto close etc normal ........................................................ 
Comments ............................................................................................................................................
..............................................................................................................................................................
..............................................................................................................................................................
Service performed by...........................................................................................................................

17
7. W ARRANTY
a. Gate Drive Systems Australia warrants that the goods manufactured by it shall be free from defect in
manufacture for a period of 12 months from the date of invoice. Should any fault occur within that period as a
result of faulty workmanship or materials, Gate Drive Systems Australia will at its discretion, replace the
product at no charge to the Customer except for installation and freight. The appropriate Serial Number must
be quoted for all warranty claims.
b. For the goods not manufactured by Gate Drive Systems Australia, we shall pass on the manufacturers warranty
to the Customer from the date of invoice. It is at the manufacturers discretion to repair or replace goods deemed
to be defective as a result of faulty workmanship or materials.
c. All goods must be returned to Gate Drive Systems Australia or its representative for inspection or testing to
assess if a claim is justified. It is the responsibility and at the cost of the Customer, to remove and return the
goods for inspection and freight costs are the responsibility of the Customer.
d. The warranty is negated and will not apply in the following circumstances:-
i. If no proof of date of purchase can be produced.
ii. If the product has been used in a manner beyond its design parameters.
iii. If the product is tampered with or repaired by personnel not authorised to do so.
iv. In respect of loss or damage caused by rough treatment.
v. If the product is not used and maintained in accordance with instructions or recommendations listed in
this Installation and Maintenance Manual.
vi. In respect of loss or damage caused by an Act of God or any other cause not within the manufacturers
control.
e. Goods returned under warranty for repair or testing will incur a charge to be fixed by the manufacturer if no
fault is found.
f. The Customer shall bear freight charges for removing and returning the goods for inspection and for the
delivery and installation of any replacement or repaired product from a justified warranty claim.
g. Save for the express conditions and warranties herein contained all other conditions or warranties (whether as
the quality, fitness for purpose or any other matter) expressed or implied by statute, common law, equity, trade
custom, usage or otherwise are hereby expressly excluded provided that nothing in these terms and conditions
shall exclude or limit any breach or condition implied by law, the exclusion or limitation of which is not
permitted by law.