GDS GDS 4LV Manual

Installation and Maintenance Manual
Industrial Swing Gate Operator
Made in Australia from Australian & quality imported components
Installation and Maintenance Manual
Industrial Swing Gate Operator
Model: GDS 4LV
(ATA CB-6 controls)
Made in Australia from Australian & quality imported components
A.B. . 62 059 806 405
Jan 2016 V1.01
N14870
Installation and Maintenance Manual
Industrial Swing Gate Operator

2
CO TE TS
Section o: Page o:
1 Safety Precautions 3
2 Specifications 4
3 Installation Details 4-7
Electrical Cabling
Mechanical Installation
Electrical Connections
4 Commissioning 8
5 CB-6 control board layout 9
6 Control circuit diagram 10-11
7 Manual Release Instructions 12
8 Maintenance 13
9 Warranty 14

1. SAFETY PRECAUTIONS
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 and Eclipse operating 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.
•Gate leaf over 2.4m in length, hould have ome form of electro mechanical, or magnetic locking
fitted to avoid po ible damage to gearbox from forcing due to vandali m, negligence, ramming,
CAUTION!
Alway incorporate the appropriate Photo Electric Cell , Induction Loop and any other afety
device to protect both equipment and per onnel. Extra caution hould be employed when u ing
operator in auto clo e 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.

2. SPECIFICATIONS
(subject to change without notice)
WEIGHT: 41kgs (including arms)
MOTOR: 24v 120w
DUTY CYCLE: 100%
SPEED: 8-12 sec/ 0o
SIZE:
NOTE:
•Specifications
based on gate height of approximately 1.8m.
•
Specifications and in particular the suggested gate sizes can vary depending upon other variables such as friction
of hinges, environmental factors, type of cladding and external influences which may assist or de
recommended gate sizes.
3. INSTALLATION D
ETAILS
After reading the previous sections in this manual, and having checked for suitable installation, proceed as follows:
Electrical Cabling
•
A suitably rated Isolator and 240v power
is to be mounted.
•
If electrical cabling needs to be run across the driveway (where the single gate operator is on the opposite side
to the control box) then ensure the appropriate numbe
and are installed at the correct depths and manner for both the mains voltage cables and low voltage cables.
•
Wiring for photo electric cell cabling and safety induction loops etc.
(subject to change without notice)
WIRING REQUIREMENTS:
240v on Control Box side
2 – 2.5mm2 min. wires
to operator
3 – 0.5mm2 min. wires
to operator for limit
Control input cables, Output signal cables
NOTE: If the cable run is over 10m long, shielded
recommended.
based on gate height of approximately 1.8m.
Specifications and in particular the suggested gate sizes can vary depending upon other variables such as friction
of hinges, environmental factors, type of cladding and external influences which may assist or de
ETAILS
After reading the previous sections in this manual, and having checked for suitable installation, proceed as follows:
A suitably rated Isolator and 240v power
supply should be available near to where the gate operator control box
If electrical cabling needs to be run across the driveway (where the single gate operator is on the opposite side
to the control box) then ensure the appropriate numbe
r of cables (see wiring requirements) are run in conduit
and are installed at the correct depths and manner for both the mains voltage cables and low voltage cables.
Wiring for photo electric cell cabling and safety induction loops etc.
GATE SIZE:
Weight
Up to 400kg approx.
Open Bar Gate
Up to 4.5m approx.
Clad Gate
Up to 4.0m approx
4
to operator
for motor
to operator for limit
s
Control input cables, Output signal cables
NOTE: If the cable run is over 10m long, shielded
cable is
Specifications and in particular the suggested gate sizes can vary depending upon other variables such as friction
of hinges, environmental factors, type of cladding and external influences which may assist or de
grade the
After reading the previous sections in this manual, and having checked for suitable installation, proceed as follows:
-
supply should be available near to where the gate operator control box
If electrical cabling needs to be run across the driveway (where the single gate operator is on the opposite side
r of cables (see wiring requirements) are run in conduit
and are installed at the correct depths and manner for both the mains voltage cables and low voltage cables.
Up to 400kg approx.
Up to 4.5m approx.
Up to 4.0m approx
.

MECHANICAL INSTALLATION
•
Firstly determine which gate rail the operator arm is to be mounted to.
•
Run a level from the top of the gate rail across to where the operator is
to be installed onto either wall or post.
•
Draw a horizontal line on the post or wall, whic
position of the operator where the
top mounting studs
level line, so level with the top of the bottom gate rail.
•
Ideally weld the mounting plate provided to the steel post and use extra
strengthening brackets/gussets if necessary to ensure a solidly fixed
mounting plate (i.e. strengthening brackets may be required if post is less
than approximately 150mm wide).
• If
mounting to masonry or similar, either weld tags onto the mounting
plate or as a last resort fix the operator straight to the wall preferably using
suitable chemical type anchors to ensure a firm mounting is obtained.
• Fixing without mounting plate ensur
e spacers (i.e. washers or nuts)
are used between the wall and the operator to allow for the cover to fit.
•
Lift operator into position and bolt to the mounting plate.
• Turn the knurled knob
anticlockwise and position arms so they are
approx. 10o
off of being straight when the gate is fully closed.
•
Mark where the gate bracket is to be fixed onto the gate rail, ensuring
both arms are in a horizontal, level plane.
•
Fully open the gate and realign the gate bracket to the marked position to
ensure there is adequate side room for the arms to swing. If not, the last 2
steps may have to be repeated using a cut down secondary arm.
• ow attach t
he gate bracket to the gate rail with bolts suitable to handle the
load and forces the gate and operator provide. (normally 10mm).
5
Firstly determine which gate rail the operator arm is to be mounted to.
Run a level from the top of the gate rail across to where the operator is
Draw a horizontal line on the post or wall, whic
h becomes the mounting
top mounting studs
are in line with your
level line, so level with the top of the bottom gate rail.
Ideally weld the mounting plate provided to the steel post and use extra
strengthening brackets/gussets if necessary to ensure a solidly fixed
mounting plate (i.e. strengthening brackets may be required if post is less
mounting to masonry or similar, either weld tags onto the mounting
plate or as a last resort fix the operator straight to the wall preferably using
suitable chemical type anchors to ensure a firm mounting is obtained.
e spacers (i.e. washers or nuts)
are used between the wall and the operator to allow for the cover to fit.
Lift operator into position and bolt to the mounting plate.
anticlockwise and position arms so they are
off of being straight when the gate is fully closed.
Mark where the gate bracket is to be fixed onto the gate rail, ensuring
Fully open the gate and realign the gate bracket to the marked position to
ensure there is adequate side room for the arms to swing. If not, the last 2
steps may have to be repeated using a cut down secondary arm.
he gate bracket to the gate rail with bolts suitable to handle the
load and forces the gate and operator provide. (normally 10mm).

6
ELECTRICAL CONNECTIONS
Op rators:-
•2 x 2.5mm² min wires required for each extra low voltage motor, connected into M1, M2 DI rail terminals.
•3 x 0.5mm² min wires required for limit switch connections, connected into M1, M2 Limit DI rail terminals.
CONNECTION TO CONTROL BOARD:-
Supply
Connect a 10A 240v RCD Protected supply to Din Rail terminals labelled A & .
Connect earth to earth terminal.
Motor Wir s
Connect a minimum of 2 x 2.5mm² wires for each motor into M1, M2 DI rail terminals.
Motor Control
Connect Minimum 0.5mm wires for the motor limits into the DI rail terminals marked M1, M2 limits.
Control Inputs
The P.E, OP 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
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.
Pow ring Acc ssori s
24vdc 2A accessory power DI rail terminals are provided.
Locks & Lights
Use the lock relay output terminals on the CB-6 board to power a lock if needed, connect the locks ‘+’
wire to either the n/o, n/c terminals depending on the lock to be used, and connect the locks negative wire
to the accessory’ –‘ DI rail terminal. Viro electro-mechanical locks require n/o, magnetic locks require
n/c. The load switched by the lock output terminals must not exceed 30v AC / DC @ 5Amps. Use a light
relay module to switch the applied voltage to a light, the module plugs into the “light control relay
interface connector”, ° 22. The load switched by the light relay module must not exceed 240v A.C / 30v
DC @ 10 Amps.

7
MODE SELECTION
Using the mode selection dip-switches select the desired operating modes. ote 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 detailed installation manual for details on how to change the other parameters.
POSITIO 1 Synchronising Delay
OFF - o delay
O - Motor 1 starts to open 2 seconds* before Motor 2 and Motor 2 starts to close 2 seconds* before Motor 1.
POSITIO 2 Pulse Lock Output
OFF - Lock output is activated for the entire motor drive cycle.
O - Lock output pulses for 0.3 seconds* at the start of each drive cycle.
POSITIO 3 Light Outputs Warning
OFF - Optional light module controls a light with timer which turns light off after 60seconds*.
O - Optional light module controls a warning light which activates whenever motors are on.
POSITIO 4 Swipe Mode (OSC Input)
OFF - OSC input terminal has standard Open, Close, Stop action.
O - 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.
POSITIO 5 M 2 Outputs Status
OFF - The M2 output controls second motor
O - The M2 output controls status lights
POSITIO 6 P.E Stops Close Cycle
OFF - Activating the P.E input while motors are closing causes the motors to reverse.
O - Activating the P.E input while motors are closing causes the motors to stop but not reverse.
POSITIO 7 P.E Stops Open Cycle
OFF - Activating the P.E input while motors are opening is ignored by the controller.
O - Activating the P.E input while motors are opening causes the motors to stop.
POSITIO 8 P.E Triggered Auto Close
OFF - ot selected
O - 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*)
POSITIO 9 Pedestrian Auto-Close
OFF - o pedestrian access auto-close
O - Selects auto-close in the pedestrian access mode. (Auto-close delay time is 15 seconds*)
POSITIO 10 Standard Auto Close
OFF - ot selected
O - Selects standard auto-close mode which will close the motors after fully opening.(Auto-close delay time is
30 seconds*)

8
SETTING CYCLE TIMERS AND 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. ote 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 “RU ” position.
5. Test operation.
Make sure that the slide switch is placed back into the “RU ” 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. ote when setting the OPE , CLOSE
and PEDESTRIA 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
OP status LED on the control board will flash at 1 second intervals to assist setting times. ote when setting the
OPE 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
4. COMMISSIONING
•Position the gate so it is half way, tighten manual release knob to the point where the gate will just start to be
driven but the clutch will slip if the gate accidentally hits the gate stop too hard while setting up the limits.
•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 open LED will flash (top right hand corner) if it does not, then
reverse two of the motor wires. Once the gate reaches its full open position, the green led will stay on, also
on closing, the red close led will flash while closing and then stay on once reaching it`s full open position.
•If dual gat s, leave one side disconnected (by putting both cams on limit switches) so adjustment can be done
on one side at a time. Once each side is set, you can run both gates together then do final adjustments to suit.
•Check which limit switch stops gate in each direction and adjust cams so gate will stop in the fully open and
closed positions.
•Limit switches should not switch off the gates too soon (before reaching the stops) and conversely not too late,
so the torque limiter is operating.
•Once happy with limits settings, now set the travel time. Change the run/set switch (mode selection 1 switch)
to set. Once in set, run the gate from either the full open or closed position by pressing either the opn (open),
or the cls (close) buttons. Keep the button pressed for the complete travel distance of the gate then release
approx 5 seconds after the gate has stopped in its full open or closed position. This has to done for both the
open and close cycles.
•Tighten manual release knob and check that the torque limiter slips if there is an obstruction in the way of the
gate but there is enough drive to overcome environmental conditions etc.
•Check that all safety devices work as designed and the external locks etc lock the gate.
•Install cover using screws screwed in the front and side to hold cover firm.

9
5.

7. MANUAL R
ELEASE
•
Turn power off to the control box and isolate. Using key to open side door on gate operator cover,
•
Turn knurled disc anticlockwise for arm to be released from gearbox.
•If
a magnetic lock is fitted, turn off the power to the control box.
•
If an electric lock is fitted, release with the electric lock key provided.
The gate will now open manually. Ensure gate is held firm so it does not close on
•
To engage drive, turn knurled knob clockwise until tight. Close and lock cover door with key.
ELEASE
INSTRUCTIONS
Turn power off to the control box and isolate. Using key to open side door on gate operator cover,
Turn knurled disc anticlockwise for arm to be released from gearbox.
a magnetic lock is fitted, turn off the power to the control box.
If an electric lock is fitted, release with the electric lock key provided.
The gate will now open manually. Ensure gate is held firm so it does not close on
someone or something.
To engage drive, turn knurled knob clockwise until tight. Close and lock cover door with key.
Turn power off to the control box and isolate. Using key to open side door on gate operator cover,
someone or something.
To engage drive, turn knurled knob clockwise until tight. Close and lock cover door with key.
12

8. MAINTENANCE D
ETAILS
Failur to maintain quipm nt may r sult in injury or d ath and/or damag to
Recommended maintenance to be performed on the operator and gate are as follows:
Operator performs over 150 cycles a day
Operator performs between 100-
150 cycles a day
Operator performs between 50-
99 cycles a day
Operator performs between 20-
49 cycles a day
Operator performs under 20 cycles a day
Date:
Site ame: ................................
................................
Site Address: ................................
................................
................................................................
................................
Before
commencing maintenance on the operator, isolate the
inadvertently.
Gate hinges in good condition and oiled/greased
Gate swings freely
................................
Gate stops in good condition and not loose
Gate operator mounting bolts tight
All arm joints loose but firm
................................
o oil leaks from gearboxes
................................
Gearbox drive cogs tight on shafts
Gearbox mounting bolts/nuts tight
Inside operator and control box clean
‘
Baygon’ Surface Spray around operator and control box (not on electronics)
Torque limiter chain not loose and slightly oiled
All electrical connections tight
Limit Switches operate in appropriate positions
External safety devices work effectively
External locks operate correctly
Arm taper lock grub screws tight
General operation
i.e. speed, auto close etc normal
Wash down of control box
and cover (particularly near corrosive/sea environments)....
Comments ................................
................................
Service performed by
................................
ETAILS
WARNING!
Failur to maintain quipm nt may r sult in injury or d ath and/or damag to
prop rty and quipm nt
Recommended maintenance to be performed on the operator and gate are as follows:
-
Operator performs over 150 cycles a day
each month
150 cycles a day
every 2 month
99 cycles a day
every 4 months
49 cycles a day
every 6 months
Operator performs under 20 cycles a day
every 12 months
................................
................................................................
................................
................................
................................................................
................................
................................
................................................................
................................
commencing maintenance on the operator, isolate the
electrical supply to ensure operator will not run
Gate hinges in good condition and oiled/greased
................................
.........................
................................
................................................................
................
Gate stops in good condition and not loose
................................
................................
Gate operator mounting bolts tight
................................................................
.................
................................
................................
..............................
................................
................................
..............................
Gearbox drive cogs tight on shafts
................................................................
...................
Gearbox mounting bolts/nuts tight
................................................................
..................
Inside operator and control box clean
................................................................
............
Baygon’ Surface Spray around operator and control box (not on electronics)
Torque limiter chain not loose and slightly oiled
................................
..........................
All electrical connections tight
................................................................
..........................
Limit Switches operate in appropriate positions
................................
...........................
External safety devices work effectively
................................
................................
External locks operate correctly
................................................................
.......................
Arm taper lock grub screws tight
................................................................
.....................
i.e. speed, auto close etc normal
................................
..................
and cover (particularly near corrosive/sea environments)....
................................
................................................................
................................
................................
.......................................................................
....................................
WARNING!
prop rty and quipm nt
each month
every 2 month
s
every 4 months
every 6 months
every 12 months
................................
................
................................
............
................................
.....
electrical supply to ensure operator will not run
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Baygon’ Surface Spray around operator and control box (not on electronics)
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and cover (particularly near corrosive/sea environments)....
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13

9. WARRANTY
i. 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 at its discretion, replace the product
at no charge to the Customer except for installation & freight. The appropriate Serial umber must be
quoted for all warranty claims.
ii. For the goods not manufactured by Gate Drive Systems Australia, we shall pass on the manufacturer`s
warranty to the Customer from the date of invoice. It is the manufacturer`s discretion to repair or replace
goods deemed to be defective as a result of faulty workmanship or materials.
iii. 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 & return the
goods for inspection and freight costs are the responsibility of the Customer.
iv. 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.
v. Goods returned under warranty for repair or testing will incur a charge to be fixed by the manufacturer if no
fault is found.
vi. The Customer shall bear freight charges for removing & returning the goods for inspection and for the
delivery & installation of any replacement or repaired product from a justified warranty claim.
vii. 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.
14