REMEZ REMEZ GATE OPERATORS SWING GATE MOTORS REMEZ STANDARD / FAST / HEAVY DUTY SWING GATE MOTORS 220 VOLT A/C AND 12 VOLT D/C

Transcription

1 REMEZ GATE OPERATORS SWING GATE MOTORS REMEZ STANDARD / FAST / HEAVY DUTY SWING GATE MOTORS 220 VOLT A/C AND 12 VOLT D/C REMEZ DOMESTIC LIGHT DUTY SWING MOTORS 12 VOLT D/C Remez Gate Operators Installation / Commissioning

2 INSTALLATION OF SWING GATE MOTORS INTRODUCTION The successful operation of any automation depends to a great deal on the installation. 1. Ensure that the correct motor has been chosen for the particular application. Important factors to consider when measuring up a SWING gate for automation are laid out later. 2. Plan the job carefully. Time costs money and if all the different steps to complete the automation have not been carefully thought through, unnecessary time will be wasted. In other words each step must be carefully planned. 3. Read the Manual. Follow the guidelines laid out in the installation manual, in other words if in doubt "Read the manual". Not only will a thorough understanding of the installation procedure result in reliable operation of the system, there are many safety requirements, which must be adhered to as detailed. WORK NEATLY Take care always to complete each step of the installation to the best of your ability. This includes among many things making sure that: The operator and rack are securely installed, straight and level. Cabling is color-coded, the correct cabling is used and the cabling is neatly routed and terminated. Any concrete works properly finished off. All bare metal parts are painted after the installation using a suitable primer and finishing coat. Remez Gate Operators Installation / Commissioning

3 Take pride in the work that is done and make sure that each installation can be used as a future reference. DO THE JOB RIGHT THE FIRST TIME! Important Safety Instructions SUMMARY OF INSTRUCTIONS UNDERSTAND FULLY ALL THE INSTRUCTIONS IN THE MANUAL DON T LET CHILDREN OR PETS PLAY IN THE VICINITY OF THE GATE WHILE DOING THE INSTALLATION BEFORE ATTEMPTING ANY WORK, CUT ELECTRICAL POWER TO THE OPERATOR AND WHERE APPLICABLE DISCONNECT THE BATTERY. MAKE SURE THAT SAFETY DEVICES SUCH AS INFRA RED BEAMS WILL BE INSTALLED OR AS A MINIMUM, HAVE BEEN RECOMMENDED TO THE CLIENT. MAKE SURE THAT THE OPERATION OF THE SYSTEM IS CLEARLY EXPLAINED TO THE END USER AT THE TIME OF HANDOVER. FACTORS TO CONSIDER WHEN SPECIFYING A SWING GATE OPERATOR? Type of Load. When automating a SWING gate it is important to understand the type of load that exists. A gate whether it is a swing or slider is known as an inertial load. In layman's terms this means that majority of the effort is required to get the gate moving with minimal effort required to keep the gate moving. There are three measurements used to describe the loading of the gate. 1. The MASS of the Gate. It is measured in kg, where the mass determines the inertia of the system. The gearbox and gear set must suitably strong enough to withstand the inertial forces generated by the gate. 2. Pull Force. It is measured in kgf (kilogram force), where this measurement is of the friction presented by the hinges and wind resistance. The motor of the operator must be able to develop sufficient torque to overcome the friction in the gate and get the gate moving and keep the gate moving. Remez Gate Operators Installation / Commissioning

4 Examples to consider: A heavy gate, which has been properly installed and swings very smoothly, might be perceived to be adequate for a smaller operator even if the motor of the operator can drive the gate. However will the gearbox and gear set of this operator be strong enough to handle the inertial load of this big gate. On the other hand consider a gate installation where the gate is very light but badly installed such that the gate slides very poorly with lots of friction. Even if a small operator can handle the inertial load of the gate, will the motor be strong to move the gate? 3. Duty Cycle / Gate Usage. Very simply when specifying a gate operator it is important to determine how often the motor will be required to operator per day. Duty cycle is the percentage of time the motors operates relative to the total time. The total time being the run time plus the time that the gate stays open and closed. In the case of domestic installations this very seldom a consideration. However from light industrial; to heavy industrial applications, usage can be a very limiting factor for the operator. Unfortunately in many high frequency applications the situation is aggravated by the fact that the operating time is not evenly spread over a 24 hour period. It occurs in peaks. Take for instance a townhouse complex. Majority of the openings and closings occur for say an hour, when the residents leave in the morning and similarly a peak period in the afternoon, when they return. Depending on the environment, during these peak times the motor could operate almost continuously, and if the motor does not have a sufficiently high duty cycle rating it is likely to shutdown prematurely due to thermal overload. What are these limitations? In case of AC motors, it is the heat generated by the motor when it is operating. When used excessively the motor overheats and shuts down. For a specific application the operator selected must be able to sufficiently dissipate the heat generated due to the number of operations without going into "thermal overload". AIR COOLING Your basic operator is purely air-cooled. It relies on natural convection to cool the motor. This type of cooling is not very effective particularly as the motor is enclosed within the cover of the operator, allowing very little air circulation. The duty cycle of air cooled motors varies from 20% to 40%. Remez Gate Operators Installation / Commissioning

5 FORCED AIR COOLING This operator is an air-cooled unit except there is fan which blows air over the motor. Depending on the efficiency of the airflow and the volume of air that the fan can deliver the convection cooling process cab be significantly improved and in some instances motors can operate at a 100% duty cycle. With DC motors, although the motor runs very cool, the power supply is the limiting factor. Battery driven systems: The battery, which is the primary power source, will only have a small trickle charger re-charging the unit. Therefore the battery must have sufficient capacity to cope with the usage during a specific period of time without relying on the trickle charger to re-charge the battery during this period. Having selected the correct capacity battery it is then necessary to ensure that the trickle charger recharge the battery each day taking into account. SUMMARY If confronted with an installation where the duty cycle poses a problem, how can one solve it? Install a cooling fan - this option is only open if the motor is air-cooled. It does not help to try to force cool an oil-cooled operator. Adjust the auto close time. If one can hold the gate open for a longer period of time allowing the motor more time to cool, the duty cycle will improve. PRE-INSTALLATION CHECK OF THE SWING GATE 1. PROPER REAR MECHANICAL END STOP FITTED. 2. GATE IN MANUAL MODE SWINGS FREELY. 3. GATE SWINGS LEVEL (USE A SPIRIT LEVEL) 4. BATTERY CHARGING PROPERLY (13.6V) 5. BATTERY VOLTAGE WITH MOTOR RUNNING (12V or more) 6. ENSURE THERE IS A GAP BETWEEN LEAVES. CABLE REQUIREMENTS 220 VOLT AC MAINS SUPPLY REQUIRED FOR REMEZ 1103 / 1105 / 2105 / 2115 GATE MOTORS Cabling is an important aspect of the installation to ensure a reliable system. Most importantly is the AC mains supply to the operator. It is critical that the correct cabling and procedures as detailed below are followed. This is the most commonly installed system as in many instances the gate installation requires a mains supply for powering courtesy / security lights at the entrance. Remez Gate Operators Installation / Commissioning

6 What are the cabling and procedural requirements? a) It is always recommended to use three-core steel wired armoured cable (SWA) between the house and the gate. The armouring provides the cabling with adequate protection against a person accidentally cutting the cable and being electrocuted. In addition it provides a very effective metal screen against secondary lightning surges being induced in the cable. To be buried 500 mm below the surface. b) An alternative to SWA cable is Norsk or Surfex cable. This cable is available with three insulated conductors for LIVE, NEUTRAL and EARTH. The cable has a thin aluminum foil sheath around the conductors and then a final insulating PVC layer. The cable does not provide the same mechanical strength as SWA cable and therefore can only be used as an outside cable if buried 500 mm underground. The aluminum foil provides a certain amount of screening against surges. c) At the gate the mains supply cable whether SWA or Norsk must be routed via a double pole isolator before terminating onto the gate operator. The double pole isolator for switching both the LIVE and NEUTRAL supplies must be housed in its own weatherproof housing and mounted within 1m of the motor. d) At the house or main building of the installation, the mains supply cable must be terminated via a circuit breaker inside a distribution board of the mains reticulation. e) The circuit breaker must be rated to protect the cable used between the house and gate against the highest current envisaged to be drawn by the system. The cable thickness is similarly determined according to the envisaged load to be drawn at the gate. Although the gate operator will require no more than 0.5mm2 cable, to allow for courtesy lights or other peripherals to be fitted no less than a 1.5mm2 should be specified. If the distance between the distribution board and the gate is more than 50m this cable thickness should be increased to 2.5mm2. CABLE REQUIREMENTS 12VOLT DC SUPPLY REQUIRED FOR REMEZ 1250 / 2105 D/C / 2210 GATE MOTORS Low Voltage Supply to the Gate (Applicable to 1250 / 2105 D/C / 2210 gate motors only) This option is only available to battery driven systems where the battery is the primary power source. The mains supply required is openly to trickle charge the battery and therefore it is sufficient to run a low voltage feed to the gate to operate the charger unit. The type of installation has the following advantages: It is not necessary to have an electricians certificate / qualifications to make this installation. Remez Gate Operators Installation / Commissioning

7 It is less expensive as it is not necessary include components such as circuit breakers and double pole isolators. a) Recommended is the use of three-core steel wired armoured cable (SWA). Besides the armouring giving the cable adequate mechanical strength against accidental cutting, the armouring provides excellent screening against induced lightning. b) However as the supply to the gate is safe low voltage, the Norsk cable referred to above is more than adequate from a safety consideration. However to reduce the incident of induced lightning it is still recommend to bury the cable as deep as possible in the ground. c) At the gate, the cable can be terminated directly onto the controller. d) At the house or building the cable is terminated onto a "plug in transformer" and plugged directly into a standard 15-amp plug point. e) Cable thickness: As it is a low voltage feed between the plug in transformer in the house and the charger unit at the gate, the current flow required to re-charge the battery is proportionally higher. The minimum thickness of cable that can be used is 1.0 mm2. if the distance between the transformer and the gate operator is greater than 40m then a 2.5mm2 cable is recommended. Solar Charging System (Applicable to 1250 / 2105 D/C / 2210) A major benefit of the battery driven system is that in applications where there is a large distance between the house and the gate making the cost of cabling very high, alternative power source such as SOLAR CHARGING can be used. The type of installation has the following advantages: It is not necessary to have an electricians certificate / qualification to make this installation. The system is less susceptible to lightning strikes as there are no long cable feeding into the unit, which can act as aerials for picking up induced lightning surges. A disadvantage of the solar installation is that the capital cost of the equipment is high and it is only offset by not having to install cabling between the house and the gate. If however communication equipment such as an intercom is required, cabling and cabling trenches needs to be installed, then option 2 becomes a more viable route. Cabling and equipment requirements for solar system a) Typically a 20-watt solar panel will provide adequate charging of the battery in a domestic application where the daily usage does not exceed 15 cycles. For bigger installations. b) The solar panel must be supplied with a dedicated high efficiency solar regulator. c) No less than a 45amp Hour DEEP CYCLE battery should be installed. A separate weatherproof enclosure will be required to house the battery. Remez Gate Operators Installation / Commissioning

8 Refer to the solar panel selection guide for more information about the mounting position and angles of the solar panel etc. Other cabling - refer to the cable guide provided in the respective installation manuals and note the following: CABLING FOR ACCESSORIES For infra red beams, radio receivers, loops, intercoms, switches, keypads etc always use a multi stranded insulated wire - size 0.5 mm2. CABLE ROUTING Never forget to install the cabling before throwing the final concrete to secure the foundation plate. Feed through the cable plate sufficient length of cable in order to be able to route the cable neatly into the operator. Allow +/- 380mm length where 350mm of the outer sheathing is stripped back leaving only 30mm of the full thickness of the cable sticking above the plate. It is recommended that the cable is stripped prior to installing the gearbox. Ensure that the cable entry holes are properly sealed with silicon to prevent the ingress of insects. Although there is space allowed to route cabling into the gate motors, it is important to: Only route the cables that are needed to terminate onto the control board. Route the cable up in front of the battery and make sure that they are fed through the slots provided on the controller plate (1103 / 1250) Ensure that the wires are not under tension when terminating onto the controller. Allow a large radius half loop in each wire before each termination. Remez Gate Operators Installation / Commissioning

9 SELECTION OF SUITABLE REMEZ MOTOR Armed with the above information now choose a suitable Remez Swing Gate Motor 2210 Remez Light Duty D/C 12 volt battery operated system. This system is suitable for small unclad gates where convenience is paramount to security, however, additional security can be installed in the form of an electromechanical lock which is controlled by the control panel Remez Heavy Duty D/C 12 volt battery operated system. This system is suitable for small to large clad or unclad gates. There are three versions of this model. i) Standard opens in 16 seconds for light to medium gates (Domestic) ii) Fast opens in 8 seconds for light to medium gates (Domestic and Complex) iii) H/D opens in seconds for heavier gates ( Domestic and Complex) Special situation like Out opening and under gate operations can be used with these motors. For more information consult your nearest Remez dealer / 2115 Remez 220 volt operated systems. i) Remez Standard 220 volt A/C swings, open in 15 seconds, light to medium gates. ii) Remez 210-Fast 220 volt A/C swings, open in 7 seconds, light to heavy gates. iii) Remez 2115-Heavy Duty 220volt A/C swings, opens in 23 seconds, heavy gates or gate with high duty cycle or in windy areas. APPROXIMATE SIZES AND WEIGHTS OF GATES SINGLE SWING MOTOR 220 Volts 2105 (See through gate, UNCLAD) 350kg Long Arm 4m x 2.3m DOUBLE SWING MOTOR 22O Volts 2105 Standard (see through gate, UNCLAD) 350kg Short Arm 2.5 m x 3m 2105 FAST (see through gate, UNCLAD) 350kg Short Arm 2.5 m x 3m 2115 Heavy Duty Swing (Solid Gate, CLAD) 800kg Long Arm 4m x 3m 2115 Heavy Duty Swing (Solid Gate, CLAD) 500kg Short Arm 2.5m x 3m 12V DC SWING 2210 DOUBLE SWING 350KG 3m X 1.8m 2105 DOUBLE SWING D/C 12V kg 3m X 3m Remez Gate Operators Installation / Commissioning

10 MOTOR POSITION NORMAL OPERATION L OR FEN PILLAR A HINGE GATE CLOSED B = 500 mm FROM HINGE C = 500 mm FROM HINGE D GATE OPEN MOTOR SHAFT F D1 A = B = C = D = D1 = F = B = C = D1 = Hinge of gate. STANDARD ARMS: Measure 500mm from center of hinge to B. Make a mark on the gate and on the ground at C. Open gate and mark 500mm on the ground at C. Draw a line from B through C to D. The motor drive shaft D, must be placed on the diagonal line with the Tube / Pedestal facing the gate hinge. Minimum distance between wall and gate, in the open position, is 660mm. If you can cut through the wall, to allow free movement of the swing arm, the minimum distance would be 410mm. Minimum 100mm MOTOR BOX TO PROTUDE FROM THE GROUND A MINIMUM OF 200mm 1000mm 1000mm 1260mm or 800mm. LONG ARMS Remez Gate Operators Installation / Commissioning

11 MOTOR POSITION OUT SWINGING GATES HINGE 500mm PILLAR C B GATE Bracket 360mm D 100mm R EMEZ C Aluminum cover Motor Shaft 1) Measure 500mm between point "A" (center of hinge) and "B" on gate. "B" is the position of your gate bracket. 2) Measure and mark a point "D" from "A" when the gate is in the open position. 3) Measure and mark point "C" 100mm from "D". 4) Shaft must be on point where line "D" crosses "C" 5) Arm to use must be 150mm long. 6) Pipe must be +/- 1.5m long. (adjusted to fine tune) HINGE 500mm PILLAR PILLAR GATE PIPE ARM REMEZ Aluminum cover Remez Gate Operators Installation / Commissioning

12 MECHNICAL MOUNTING DETAILS INSTALLING THE FOUNDATION BOX. Min 100mm of box to protrude from ground Solid concrete base must be used to set box Before any concrete is thrown please ensure that all cables/conduiting are in place and sealed. LIGHTNING PROTECTION When installing a gate system guarding against lightning is particularly important to increase the longterm reliability of the system. Lightning protection should be designed into the installation from the start. As mentioned earlier the type of installation of the mains supply cabling plays an important role in reducing the incidence of induced lightning surges. Screened cable always recommended where the screening of the cable must be effectively earthed. The cable must be buried as deep as possible into the ground. Recommended 500 mm below ground level. The lightning protection circuitry built into the ALL Remez gate controllers requires good earthing to be effective. The most effective earth to use is the mains supply earth. However as the length of the mains supply cable increases, the effectiveness of this earth reducers. Therefore it is always recommended to install a I meter earth rod right next to the operator using a 4 mm2 copper earth wire to link the earth rod to the earth connections inside the operator. In addition or alternatively if it is possible to identify a metal water line close to the operator this would be preferable to the earth rod. In bad lightning areas it is also recommended that an additional "lightning surge arrestor unit "(40ka double pole device) connected inside the operator between the mains supply and the charger. Make sure that the earth of this device and the other earth points inside the controller are firmly bonded together and kept as close as possible to the earth spike. Remez Gate Operators Installation / Commissioning