ECA Electronic Engineering Pty. LTD. Australia Tel: 03-95720 535 Fax: 95 720 536 Owner s Manual For SOLAR BOOM GATE Model: CA-5000 SOLAR ( 2009 / Version 1 ) 1
1 Introduction 1.0 Control PCB Wiring INSTALLATION MANUAL for ECA Solar Boom Gate MODEL: CA-5000 1.0.1 Make sure to connect the positive terminal of the batteries to the RED wires and the BLACK wires to the negative terminal of the batteries. => Warranting! Wrong connection may cause damage to the battery. 1.0.2 Connect the solar panel s wire to the terminal J2. Solar Panel + Input - Anti-Crash sensor adjustment Battery Plug 2
2.3.3. Connections in the control panel Input / output LIGHT output STOP input OPEN input CLOSE input PHOTO SENSOR Input Description Normally Open and Common for switching ON and OFF the Photo Sensor during operation. Connect to N.C. push button and to GND to Stop the gate. Jumper this input to GRD if not in use. Connect to N.O. push button and to GND to Open the gate. Connect to N.O. push button and to GND to Close the gate. Connect to the Normally Close contacts of the photo sensor s relay. Jumper this terminal to GND if photo sensor has not been used, otherwise, the systems wouldn t operate. P.B.1 Input Connect to Normally Open Push Button to open and close the gate for manual operation. P.B.2 Input Connect to Normally Open Push Button or to the intercom system s relay (must be voltage free contacts) to operate the pedestrian mode to open 1m only. Ant. Input Antenna input. Connect to External Aerial Model ANT-433 for extending operation range. 3. Automatic SETUP - Setting the opening & closing time After installing the boom arm, the control panel must be set to learn the opening and closing cycle time as follows: Step 1. Put the gate on manual and open the gate to half open position and re-engage the gate back in gear. Step 2. Press and release Push Button TIMER on the control panel and the program LED will turn ON. Step 3. Press and release button ( I ) on the remote control and the set-up will begin. The gate will open and close twice and the control panel will set the opening and closing time; fast and slow time automatically. 4. Operation program The control panel has three options of programs that you can choose from, for operating the gate. Program No. 1 : Semi automatic Step By Step When choosing this type of operation, the gate will open, close or stop by the command of the remote control or the manual push button only (if connected). The first command opens the gate, the second stops, the third closes the gate, and the fourth stops the operation and so on. Program No. 2 : Automatic operation For automatic closure operation. When pressing the remote control, the gate will open and stay open for a preset time, after which the gate will close automatically. 4.1. Choosing the required operation program You can make your selection by the push button PROGRAM in the control panel, as follows: Step 1. Press and release Push Button PROGRAM on the control panel and the program LED will turn ON. Step 2. Choose and press; Button ( I ) on the remote control for operation program No. 1 Or Button ( II ) on the remote control for operation program No. 2 3
4.2. Setting the auto close timer This computerized control panel has a programmable auto-close timer that can be set very easily as follows: Step 1. Press and release Push Button TIMER on the control panel and the program LED will turn ON. Step 2. Press and release button (II) on the unit s remote control and the light relay and the program LED will start to flash. Step3. Wait the period of time you wish to set the Auto Close Time (for example 15 seconds) and then press and release button (II) on the remote control once again. The PROGRAM LED and the light relay will stop to flash, to indicate that the auto close delay time has been set for automatic operation. 5. Choosing the right ramp-down speed for the boom Arm The control panel allows you to select one out of four different speeds for the arm to slow down at the end of the travel and ramp-up. To select the right speed do as follows: 1. Press and release SPEED push button in the control panel and the program LED will turn ON. 2. Press button ( I ) on the Remote control for canceling the slow down speed. 3. Press button ( II ) on the Remote control for Medium High speed slow down => 90% 4. Press button ( III ) on the Remote control for Medium Low speed slow down => 80% 5. Press button ( IV ) on the Remote control for the Lowest Speed Slow down => 70% 6. Enable / Disable the Photo Sensor function in opening mode The control panel is responding to the photo sensor in closure mode, which will open the boom gate each time the photo sensor is triggered during closure time. However, you can set the control panel to respond to the photo senor also in the opening mode. In such a case, the boom gate will stop during opening, if the sensor is triggered. You can choose and define the photo sensor s function during opening mode, as follows: Step 1. Press and release Push Button FUNCTION on the PCB and the program LED will turn ON. Step 2. Press button ( II ) on the remote control to set the Photo Sensor to be active during opening mode too. If you wish the photo sensor to be active only in closing mode repeat step 1 & 2 above. 6.1. Photo Sensor Connection In order to minimize current consumption of the safety photo sensor, the Light Relay output in the control panel, is used to switch ON and OFF the photo sensor (if in use) during the operation of the motor. The light relay will turn ON the photo sensor only during the closure time of the boom gate and switch it OFF after the boom gate is fully closed. This will insure to minimize the current consumption of the photo sensor to zero when it is not in use. See connection diagram on next page. 4
Photo Sensor Rx 1 2 3 4 5 N N C + - O C M Remove bridge when photo sensor is in use Photo Sensor Tx 1 2 + - Solar Panel s Cable Red Black + - 7. Setting and choosing features The control panel allows you to set four different functions and features according to your needs; 7.1. Setting the motor to be with or without Soft Start (ramp-up) The control panel is set to start opening and closing the boom gate with a soft start, however, you can choose to cancel this feature as follows: Step 1. Press and release Push Button FUNCTION on the PCB and the program LED will turn ON. Step 2. Press button ( III ) on the remote control to cancel the soft start. If you wish to restore this feature repeat step 1 & 2 above. 8. Anti-Crash sensor adjustment: The level of the Over-Load-Protection can be adjusted by the variable sensitivity pot on the control panel. To set the sensitivity level of the anti crash sensor do as follows: Step 1. Press the remote control to close the gate. Step 2. While closing, press with your hand against the gate to stop the gate from closing. If the gate stops with an unreasonable force, increase the sensitivity by turning the pot in the control panel to higher sensitivity level to get a satisfactory level of force. 5
9. Remote Control Teaching & Deleting the Memory The control panel s radio receiver can learn up to 160 remote controls into its memory. It can learn any of the buttons (I), (II) or (III) of the remote control (model TR-4RS) for operating the boom gate. Button (IV) is reserved for operating the boom gate partially, if required. There are two ways of teaching new remote controls: 9.1. Teaching remote controls from the control panel Press and release the REMOTE button in the control panel and the program LED light will start to flash indicating that the receiver is ready to learn the new remote control s button. Choose and press one of the buttons (I), (II), (III) or (IV) in the remote control for one second and the LED light will stop flashing to indicate that the remote control s button has been learned into the receiver s memory. 9.2. Service Free Teaching Method This method allows the end user to teach new remote controls into the receiver s memory without the need of neither a technician nor opening the control panel s box. Use an operational remote control of the unit, (a remote control that operates the unit ) to teach a new remote control into the receiver s memory as follows: Use the remote control that already operates the system and stand next to the boom gate. Press and hold both the buttons (II) and (I) simultaneously for 5 second. After releasing the buttons of the original remote control, the light relay in the control panel will start to CLICK, indicating that the receiver is ready to learn the new remote control s button. Choose, press and release for one second one of the buttons (I), (II) or (III) of the NEW remote control. The CLICK sound of the light relay will stop to indicate that the remote control s button has been learned into the receiver s memory. 9.3. Deleting all remote controls from the receiver s memory Press and HOLD the REMOTE button in the control panel till the Program LED turns on (a CLICK sound will be heard). Now, you have 5 seconds to press and release the REMOTE button once again, in order to clear the receiver s memory. If the REMOTE push button has not been pressed within the 5 seconds, the control panel will exit this mode and turn off the program LED light indicating cancellation. If you press and release the REMOTE push button within the 5 seconds, the program LED light will start to flash indicating that Clearing the Memory is in Process. Please wait one second after the program LED light stops flashing before you operate the system. ECA ELECTRNIC ENGINEERING Pty. LTD. Head office 465 Hawthorn Rd. Caulfield Sth. 3162 Vic. Australia. Tel: + 61 3 95720535 Fax: 95720536 www.gatesonsolar.com 6
GENERAL SAFETY RULES Our compliments for your excellent choice. This Solar Boom gate has been produced according to a high quality and strict reliability, that's why it will assure you long-lasting performance. This manual will offer you all the information you may need to install your barrier and to safe guard your safety. All our products have been made in conformity with the regulations in force. We recommend using original part only, during the installation and the upkeep. However, the caution is unquestionably indispensable and nothing is better than preventing accidents. IMPORTANT Any installation or repair, or adjustment of the working machinery by unqualified people is strictly prohibited unless all the necessary precautions: power supply disconnected (included possible batteries). All moving mechanism must be provided with suitable protections. ECA Electronic Engineering Pty LTD is not responsible for any possible damages or injuries to people, object or animals, caused by any use not provided for this manual and/or any unauthorized modification of the product. Keep this manual enclosing it with technical brochure of installation in a suitable place well-know by all the interested people. You have to operate the elimination of the packing material (cardboard, plastic, polystyrene, etc.) in conformity with the regulations in force, remembering that for a child a plastic envelope could be extremely dangerous. You have to teach the people employed in using the automation about the control and security systems of the installation. Don't install this product in explosive places. UPKEEP For any kind of upkeep, you have always to disconnect the solar panel and batteries. For a correct upkeep of the installation follow these instructions: Clean periodically the photocells. Checking by qualified people the electronic clutch (see the paragraph "installation of the electronic central unit"). In case of malfunction seek information from qualified people. DEMOLITION You have to operate the elimination of the materials in conformity with the regulations in force. All material must be divided by type (copper, aluminum, plastic, electrical central unit). However there are not materials considered dangerous for the handler. DISMANTLING In order to dismantle or to move away the automation, follow these instructions: Disconnect batteries and solar panel and all the electrical accessories. Dismantle the control console and all the other components of the installation. If you have noticed that some components have been damaged, you have to replace them. PRODUCT TYPE The CA45000 Boom Gate has been designed and constructed to open barrier arms up to 5 meters in length. ECA Electronic Engineering Pty LTD does not assume any responsibility for other use than the intended use of the Boom Gate. ATTENTION: The barrier is not equipped with a mechanical clutch and therefore when installed must be connected to a special ECA Electronic Engineering Pty LTD control unit only. USE OF THE MECHANISM Attention, for personnel safety it is of vital importance to carry out the following instructions. Keep these instructions in a safe place. Do not allow children to play with the fixed or remote controls of the gate. Place the remote controls out of the reach of children. As the mechanism can be controlled nearby or at a distance using push buttons or remote controls it is indispensable that the efficiency of all safety devices be checked frequently. We recommend periodical checks (every six months) by qualified personnel to adjust the electronic clutch. To adjust this protection device, see the Paragraph "Electronic clutch adjustment" in the instruction manual of the electronic control unit. PRELIMINARY CHECKS Read carefully all parts of this manual. Check that the product was not damaged during transportation. Check that the electrical plant conforms to the characteristics required by the gear motor. Check that an adequate grounding plant exists and that all metallic parts are connected to this plant. We remind you that the mechanism facilitates use of the barrier and does not resolve problems due to defects, bad installation or lack of maintenance to the barrier. LUBRICATION All ECA barriers are supplied with permanent grease lubrication INSTALLATION Important safety instructions for installation. Warning: A bad installation can cause a great deal of damage or harm. Scrupulously follow all installation instructions. ATTENTION: For any reason whatsoever never disassemble the barrier arm when it is in a horizontal position ATTENTION: For any reason whatsoever never carry out an emergency or manual maneuver if the barrier arm is not assembled ATTENTION: Do not release the motor when it's working. For correct commissioning of the ECA barriers, proceed as follows: Locate the point inside the property where the ECA barrier will be installed (figure 1). Construct a solid concrete base with the dimensions illustrated on figure 1; provide a passage for the sheath "G" of the wiring cables and system controls. Before the concrete sets, position the "Ps" plate (OPTIONAL) well down into the concrete making sure that the plate is correctly oriented and perfectly horizontal on both axis (picture 1). 7
If a flat solid base is already available on the ground, the barrier can be fixed directly to the base by screws and fixing plugs without using the "Ps" plate. Unscrew the 2 screws "V1" by the supplied Alien key "CH1'.' and remove the "Cp" protection cover and the front door to gain access to the internal cabinet of the barrier (picture 2). Once the concrete has fully set, position the PUNTO barrier onto the "Ps" plate or onto the fixing plugs and tighten the nuts supplied "D" or the plug screws (picture 3). Barrier must be leveled in up right position and turned according to boom selected direction. IN VERTING THE BARRIER OPENING DIRECTION CA5000 barrier is supplied for opening in an anticlockwise direction picture 4. To invert the opening direction proceed as follows: Remove the boom from the barrier before doing the operation of inverting its way of opening from position "A" of the lever "Ls" the spring "Mb" by removing the screw "Vm" (picture 4). Carry out an emergency or manual maneuver (see paragraph Emergency or manual maneuver) and turn the lever "Ls" clockwise by 90 Reassemble the balancing spring "Mb" in position "B" and lock the "Vm" screw (picture 5). BARRIER ARM ADJUSTMENT AND BALANCING Warning: when boom is down, the spring Mb must be under tension (pic 4 and 5); when boom is up, the spring Mb but be released. Assemble the barrier boom and block it. Make an emergency or manual maneuver (see paragraph Emergency or manual maneuver) checking that the boom, from its horizontal position, goes up slowly. In case the boom doesn't go up, (after the arm has been brought to the up right position to unload the spring) Adjust the spring adjuster "T1" (pic. 4-5) increasing the spring tension. ADJUSTING THE MECHANICAL STOPS Carry out an emergency or manual manoeuvre (see paragraph Emergency or manual maneuver) and bring the arm to a vertical position. Using two 17 mm spanners loosen the locking nut "D1" and screw in or out the adjusting screw "F1" until the desired vertical stop position is obtained and then tighten the nut "D1" (pic. 4-5). Bring the barrier arm to a horizontal position, loosen the nut "D2" and adjust the stop "F2" until the desired horizontal stop position is obtained and then tighten the nut "D2" (pic. 4-5). Once the above operation is terminated, carry out a manual opening and closure maneuver to check that the mechanical stops are in the correct position. Be sure that in closing position, the switch "Ms1" has to be touched by cam "Cs". If not, adjust the cam "CS" unscrewing screw "V2" until the cam touches the micro switch "Ms1" (pic. 6) ELECTRICAL CONNECTIONS Carry out electrical connections as shown in the manual of the electronic control unit and bearing in mind the characteristics required by the general assembly drawing. ADJUSTMENT OF ELECTRICAL LIMIT SWITCHES CA5000 is provided with opening and closing limit switches, which control the start of the slow-down cycle of the bar (with anti-clockwise opening as supplied by the manufacturer, limit switch MS1 CLOSE, MS2 OPEN) while the limit switches are not in use, the bar moves at normal speed, as soon as they are employed the stow-down phase of approach to the mechanical stop commences. Move the bar to the desired position for the start of the closing slow-down phase manually, and adjust the corresponding cam CS until the limit switch is triggered. Move the bar to the desired position for the start of the opening slow-down phase manually, and adjust the corresponding cam CS until the limit switches are triggered (figure 6). Carry out an automatic operation and check the exact position of the cams. TESTING Starting from the barrier closed position, carry out complete OPEN and CLOSE cycles to check for correct positioning of the limit switches and the function of the safety devices installed. Reassemble the front door and the protection guard "Cp'.' Instruct all personnel involved with operating the mechanism about the commands, safety devices, emergency maneuver and danger involved when operating the mechanism. Fill in the technical file for the installation and fulfill any obligations required by regulations in force. Correct functioning of the CA5000 barrier is guaranteed only and exclusively when equipped with ECA safety devices and only when equipped with an original Control Panel. EMERGENCY OR MANUAL MANOEUVRE An emergency or manual maneuver is carried out during the installation stage and only in the case of malfunction of the mechanism or in the absence of electrical power. ATTENTION: Do not release or put in automatic the motor when it's working ATTENTION: Never carry an emergency or manual maneuver if the barrier arm is not assembled. ATTENTION: Never disassemble the barrier arm when it is in a horizontal position. Disconnect power Insert the special "Ch" key in to the "Sb" lock and turn it in an clockwise for 180 until the mechanism unlocks (picture 7). Remove the pawl from the lock and insert the Alien key CH1 in the hole until you reach the proper place (pic.8). Turn the key CH1 anticlockwise until its end and lift the boom up manually. To put the barrier in automatic, turn the key CH1 clockwise until its end. Take the key CH1 off, re-fit the pawl into the lock SB and close the protection lid TA. Keep the "Ch 1" key in a safe place that is known only to the personnel who can operate the mechanism. Reconnect the power making sure that no personnel are in the area where the barrier is moving. ECA ELECTRNIC ENGINEERING Pty. LTD. 465 Hawthorn Rd. Caulfield Sth. 3162 Vic. Australia. Tel: + 61 3 95720535 Fax: 95720536 www.gatesonsolar.com 8
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