MicroTeq GEMINI 220 V User manual

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NOTES

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CONTENTS
NOTES 1
CONTENTS ................................................................
.........................
2
FEATURES ................................................................
..........................
3
Introduction ................................................................
................
3
Physical Dimensions ................................................................
..
3
Technical Specifications ................................
............................
4
STANDARD INSTALLATION KIT ................................
........................
5
WARNINGS ................................................................
.........................
6
INSTALLATION OF THE UNIT ................................
............................
7
Initial preparations for Mounting the Base Plate
........................
7
Mounting the Rack ................................................................
.....
8
Connecting the 220 V Electrical Supply ................................
....
9
Other Connections ................................................................
.....
10
Setting the Remote Control Security Code Dip Switches
..........
10
Programming a GEMINI Remote Control ................................
..
10
Fitting the Alluminium Stoppers ................................
.................
12
Reversing the Electrical Motor Direction ................................
...
12
Obstruction Sensing Adjustment ................................
...............
13
Setting The Auto Close Dip Switches ................................
........
14
OPERATING PROCEDURES ................................
.............................
16
Initial Testing Procedures after Installation
................................
16
Daily Operation ................................................................
..........
16
LED Display ................................................................
...............
17
TROUBLE SHOOTING GUIDE ................................
...........................
18
Table 1: Problems during the Installation/Operating Phase
......
18
MAINTENANCE ................................................................
...................
21
Replacing the Remote Control Battery ................................
......
21
ELECTRICAL DIAGRAM ................................................................
.....
22

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FEATURES
INTRODUCTION
The GEMINI 220 V sliding gate system is a self contained unit which
comprise of a single 220 Volt AC electrical motor that drives the rack pinion
via a gearbox. The gearbox, electrical motor and associated components
are mounted in a rust treated base box. The base box is secured to the
base plate, which in turn is cemented or bolted to a concrete base. The
complete unit is enclosed with a weather resistant lid.
The GEMINI system is rigidly build for reliability, but with safety as first
priority. The electronic control card in conjunction with the limit switches
makes provision for the several unique features, such as remote controlled
gate opening, pedestrian opening facility, obstruction (“impact”) sensing,
adjustable “auto close” facility, infra red obstruction sensing facility
(optional) and normal push button operation.
PHYSICAL DIMENSIONS

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TECHNICAL SPECIFICATIONS
STANDARD HEAVY DUTY
Motor
..............................
220V single phase
Gearbox
.........................
Oil filled WORM DRIVE
Gear ratio
.......................
30:1 45:1
Gate speed
......................
12 meter per min 10 meter per min
Torque
............................
±50 N.m ±60 N.m
Maximum gate weight
....
600 kg *1 200 kg *
Electricity consumption
..
±2,8 A
Motor size
.......................
370 Watt
Duty cycle
.......................
65%
Motor protection
.............
Thermal overload
Limit switches
.................
Independent in both directions, each with a
double action for additional reliability
Obstruction
.....................
Mechanical adjustable obstruction sensing in
both directions. Can accommodate I/R beam
sensors
Activation
........................
By using any N/O electrical circuit, push button
or remote control
Other characteristics
......
i. Automatic closing facility
ii. LED display for gate mode
iii. Mechanical override in case of a
malfunction or power failure
iv. Pedestrian opening facility
v. Provision for external light
Weight
............................
±23 kg (Includes rack and base plate)
*Provided that track wheels with a minimum diameter of 76 mm, fitted with
roller bearings on a straight and level track are used. Gate must move
with ease.

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STANDARD INSTALLATION KIT
Your GEMINI 220 Volt AC sliding gate opener system comprise of the
following:
1. Weather resistant lid.
2. Rust treated base box.
3. Base plate with attachment bolts,
or
3a. Alternative base plate for concrete
mounting.
4. Manual override lever and padlock
lug.
5. 220 Volt electrical motor.
6. Gearbox.
7. GEMINI electronic control card.
8. MAINS connector block.
9. Gate obstruction (“impact”) switch.
9a. Gate obstruction sensing
adjustment.
10. Gate “open and close” limit switch
spring.
11. Remote control transmitter. ***
12. Remote control receiver. ***
13. Alluminium limit stops. **
14. Rack. **
15. Angle iron brackets (weld item). **
Items marked with ** are loose items but part of the kit, and items marked with *** are
not part of the kit.

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WARNINGS
NEVER WORK ON THE SYSTEM WITH THE ELECTRICAL POWER ON.
NEVER ALLOW PERSONS OR ANIMALS TO STAND ON THE GATE OR
TRACK WHILE THE GATE IS IN MOTION.
KEEP HANDS CLEAR OF THE RACK AND PINION GEAR WHILE THE
MOTOR IS IN OPERATION.
DO NOT ALLOW ANYONE TO PUT THEIR HAND THROUGH THE GATE
TRELLIS WHILE GATE IS MOVING.
TEST ALL OPERATING SYSTEMS ON A REGULAR BASIS,
ESPECIALLY THOSE RELATED TO THE SAFETY FEATURES.

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INSTALLATION OF THE UNIT
INITIAL PREPARATIONS FOR MOUNTING THE BASE PLATE
To determine the position for installing your GEMINI, fully close the gate
and place the unit (with base plate attached) in position so that the pinion
gear is approximately 15 mm away from the gate. Locate the base plate
against the existing gate track (the base plate is to be welded to this track
at a later stage).
NOTE
The securing holes in the base box are slotted; ensure that
the base plate bolts are located in the center of these
holes and that the base box and base plate are parallel.
Ensure that the centerline of the gate is parallel with the centerline of the
pinion. This will ensure that the centerline of the rack will run on the
centerline of the pinion.
Clearly mark the position of the base plate. Remove the complete unit and
prepare a foundation for the base plate. Consult your local Builders Supply
Store for the necessary information on concrete strengths, mix ratios and
hardening times.
NOTE
Install conduit piping in the foundation to correspond with
the opening in the base box, through which the electrical
cables are routed.
Remove the base plate from the unit.
Cast concrete into the previously prepared foundation. Ensure that the
exact position (previously marked) is maintained to ensure correct
mounting of the unit.
Stitch weld the base plate to the existing gate track.
Mount the GEMINI on the base plate and align as previously described.

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MOUNTING THE RACK
Starting at one end of the gate, weld the rack in position by using the angle
iron brackets. The following critical points must be considered:
When determining the position of the rack, the manual override
lever must be in the upright position.
The angle iron brackets must not be more than 600 mm apart.
Allow a free play of approximately 1 mm between the pinion and
the rack.
When moving the gate to the next position, the manual override
lever must be lowered.
For wooden gates, drill two holes in the angle iron bracket and
secure to the gate with wood screws. To prevent the gate from
burning, mark the position of the angle brackets and weld to rack
before securing to the gate.
Once the rack is in position, ensure that the unit (pinion) is correctly aligned
with the rack. Final adjustments can be made by sliding the unit in the
slotted holes to achieve the correct alignment. Tighten the mounting nuts.

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CONNECTING THE 220 V ELECTRICAL SUPPLY
CAUTION
Under no circumstances must the main electrical supply
be wired directly from a power source. As a safety
precaution, an ON/OFF switch must be incorporated into
the electrical circuit, normally within 1 meter from the unit.
Electrical power supply - Connect to the two terminal blocks
marked: 220V MAINS.
Ground (earth) connection - Connect the ground (earth) wire to
position marked: GRND.

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OTHER CONNECTIONS
220 V Light - Connect to terminal blocks marked:
220 V LIGHT. Light will be activated when the
gate is opened and switches off ± 3 minutes after
the gate has closed.
Pedestrian Facility - Connect to terminal blocks marked:
COMMON and PED.
Push button - Connect to terminal blocks marked:
COMMON and TRIG.
Infra red sensor - Connect to terminal blocks marked:
COMMON and I/R BEAM.
Loop detector - Connect to terminal blocks marked:
COMMON and TRIG. (Depending on
Application)
Receiver - Plug in on electronic control card where marked:
RX IN.
External LED Connect to electronic control card as illustrated
CAUTION
Ensure that all the legal requirements for your local area
are complied with.
SETTING THE REMOTE CONTROL SECURITY CODE DIP SWITCHES
Once the electrical supply is correctly connected, the remote control
transmitter and receiver security code must be set. Note that the
manufacturers set all the transmitters and receivers to a standard code and
therefore it is imperative to change these codes to your own personalised
code.
If a non-Gemini remote control is used, program the remote control as per
the supplier’s instruction.
Programming a GEMINI Remote Control
Using a small screwdriver, remove the rear covers from the transmitter and
receiver. Place the units so that the numbers on the dip switches starts with
No. 1 from the left.

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On a single function transmitter, place dip switch No. 1 to the ON position.
Do the same on the receiver. From dip switch No. 2 to No. 12 place the
switches in random sequence to the ON or OFF positions. Ensure that the
receiver dip switch settings match the transmitter settings.
Your security code is now set. Replace the rear covers on the transmitter
and receiver.

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FITTING THE ALLUMINIUM STOPPERS
Position the “open and close” alluminium stops on the rack so that they will
push the limit switch spring in time to stop the gate in the correct position.
Once the stops are in position, tighten the grub screws, using an Allen key.
REVERSING THE ELECTRICAL MOTOR DIRECTION
Refer to the electrical diagram on Page 22. The electrical motor direction
default is set by positioning the gate direction jumper on the electronic
control card either to the left or right.
The electronic control card is equipped with three small pins; the center pin
is the common pin, the left hand pin for the left direction and the right hand
pin for the right direction.

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When the gate is initially activated (during installation) and the gate
direction is incorrect, the gate direction jumper must be unplugged and
moved to the opposite set of pins. Ensure that the jumper is fully plugged
in.
OBSTRUCTION SENSING ADJUSTMENT

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Obstruction sensing should be set so that the gate will stop and reverse on
impact while closing. The obstruction sensors are set at the factory, but it
will be necessary to adjust these sensors to suit your gate.
Impact sensitivity is adjusted by adjusting the screws (1) on either side of
the electrical motor.
Turning nut (2) outwards, decreases the spring (3) tension, thus causing
the impact sensing to be more sensitive. Test impact sensitivity by bumping
the gate by hand in the opposite direction of movement.
Adjust the tension of both springs until the ideal impact sensitivity is
achieved in each direction.
In extreme cases it may be necessary to adjust the micro switch lever (4)
positioned above the electrical motor.
SETTING THE AUTO CLOSE DIP SWITCHES
After your GEMINI unit has been installed and you wish to alter the time
delay for the Auto Close facility, proceed as follows:

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0 = OFF 1 = ON
SWITCH No.&
POSITIONS
1 2 3 4
TIME DELAY
(in seconds)
0 0 0 0 = Off
1 1 1 0 = 2
1 0 0 0 = 10
0 1 0 0 = 20
1 1 0 0 = 30
0 0 1 0 = 40
1 0 1 0 = 50
0 1 1 0 = 60
The dip switches are marked No. 1 to 4. Refer to the above table. Choose
a time delay to suit your personal requirements i.e. 50 seconds; dip switch
settings must be 1010.
Move the No. 1 dip switch to the ON position, the second switch to the OFF
position, the third switch to the ON and the fourth dip switch to the OFF
position. Your 50 second Auto Close time delay is now set.
Removing the Auto Close Loop on the electronic control card will disable
the auto close function even if a time delay is set.

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OPERATING PROCEDURES
INITIAL TESTING PROCEDURES AFTER INSTALLATION
1. Lower the manual override lever and move the gate to halfway open
position. Raise the override lever to engage the pinion into the rack.
2. Press the remote control button. The gate must move to the open
position and stop. If necessary, adjust the alluminium stopper position
on the rack.
NOTE
If the gate moves to the closed position on the first
actuation, the electrical motor direction is incorrectly set
and must be reversed. Refer to “Reversing the Electrical
Motor Direction” on page 12 for the correct procedure.
3. The gate will remain in the open position for the time as pre-selected
during the Auto Close dip switch settings. Gate will move to the fully
closed position and stop. If necessary, adjust the alluminium stopper
position on the rack.
4. Perform an obstruction-sensing test. If necessary, refer to
“Obstruction Sensing Adjustment” and adjust the obstruction
sensitivity.
5. Test the operation of the gate from inside the house by using the
push button.
DAILY OPERATION
1. The gate can now be operated by either the remote control or the
push button inside the house.
2. If the pedestrian facility is utilised, the gate will open for ± 1 meter to
allow a pedestrian to enter. The gate will automatically close after 10
seconds.
3. If either the remote control or the push button is pressed while the
gate is in motion, the gate will react as follows:
a. If Gate Were Closing: The gate will stop and open.

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b. If Gate Were Opening: The gate will stop and wait for the next
command. If the “Auto Close” function is selected, the gate will
close after the preset time.
4. If the gate senses an obstruction while closing, the gate will stop and
move to the open position.
5. If the gate senses an obstruction while opening, the gate will stop and
wait for the next command. If the “Auto Close” function is selected,
the gate will close after the preset time.
LED DISPLAY
6. The external LED display mounted on the electronic control card
conveys the following visual messages:
LED flashes every six seconds – gate is in the closed position.
LED flashes continuously – gate is in motion (opening or closing).
LED remains on permanently – gate is in the open position.

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TROUBLE-SHOOTING GUIDE
Should a problem occur, consult the following table first before calling your
local GEMINI agent.
The table is set out in Problem, Possible Cause and Remedy and/or Test,
to enable quick identification and location of faults. Care has been taken in
the compilation of this Trouble-Shooting Guide to include all likely
malfunctions that could occur.
WARNING
DURING SOME OF THE FOLLOWING CHECKS/TESTS, IT
WILL BE NECESSARY TO WORK ON THE UNIT WHILE
THE ELECTRICAL POWER IS SWITCHED ON (LIVE),
THEREFORE UTMOST CARE MUST BE TAKEN TO
PREVENT ELECTRICAL SHOCKS.
TABLE 1 - PROBLEMS DURING THE INSTALLATION/OPERATING
PHASE
PROBLEM POSSIBLE CAUSE REMEDY AND/OR
TEST
Electrical motor does not
turn
a. Is the main power
switched ON?
a. Switch power ON
b. Is the electrical
power correctly
connected?
b. Check and rectify as
necessary
Electrical motor turns but
gate does not move
a. Is the manual
override lever in the
UP position?
a. Move override lever
to the UP position
Power is ON (LED
indicating), but motor
does not react
a. Wiring to electronic
control card not
correctly connected
a. Check and rectify as
necessary
b. Electronic control
card defective
b. Replace electronic
control card

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PROBLEM POSSIBLE CAUSE REMEDY AND/OR
TEST
Motor operates by
activating with the push
button, but not with the
remote control
a. Is the security code
set correctly?
a. Check and if
necessary, reset
security code
b. Remote control
battery flat
b. Replace battery
c. Remote control
defective
c. Replace remote
control
Motor activates by
remote control, but not
with the push button
a. Faulty wiring to the
push button.
a. Disconnect push
button wiring from the
GEMINI and
momentarily bridge
the COMMON and
TRIG connections at
the connector block. If
motor operates, the
wiring is faulty and
must be repaired.
b. Push button faulty b. Disconnect push
button wiring at the
push button.
Momentarily bridge
the wires at the push
button. If motor
operates, the push
button is faulty and
must be repaired or
replaced
Gate (motor) direction
incorrect
a. Incorrect setting a. Refer to “Reversing
Electrical motor
Direction” and use
alternative positioning
of the jumper
Motor opens the gate for
a short travel only, then
closes again
a. Gate mass to heavy
for unit
a. Discuss problem with
your local GEMINI
agent
b. Obstruction on track. b. Clear obstruction
from track
c. Obstruction
sensitivity to high
c. Adjust obstruction
sensitivity to suit your
gate.

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PROBLEM POSSIBLE CAUSE REMEDY AND/OR
TEST
Motor makes a “clicking”
sound but does not
switches ON
a. Motor has forced the
gate against the gate
post and cannot
release by itself.
Alluminium stoppers
incorrectly adjusted
a. Lower the manual
override and move
gate away from gate
post. Adjust the
alluminium stoppers
b. A power surge has
caused a problem on
the electronic control
card
b. Switch the main
electrical power to the
OFF position and wait
10 seconds, then
switch the power to
ON again
Gate opens and closes
by itself
a. Faulty push button
wiring
a. Check and rectify as
necessary
b. Faulty remote control
receiver
b. Replace the remote
control receiver
c. Somebody in your
area is using the
same security code
as yours
c. Change your security
code
Receiver reception
insufficient
a. Transmitter battery
flat
a. Replace battery
b. Receiver range is
obstructed
b. Place in different
position
Gate moves with
difficulty
a. Wheel track is dirty a. Clean wheel track
b. Wheel track has
burrs or markings
b. Repair burrs and/or
markings
c. Insufficient free play
between pinion and
rack (wheel track has
sagged). Weight of
gate is laying on
pinion
c. Repair the sagging
problem and restore
free play between
pinion and rack