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D3, D5, A5
SLIDING GATE
AUTOMATION
Product Code: CP72SR5
INSTALLATION
MANUAL
Latest Revision: 02.02.2005
Document Ref.: 1010.D.01.00136_8
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IMPORTANT 30 Oil Specifications: GRADE: 75W90 31 Qty: 75ml 32 33 34 35 WARNING! (D5/A5 ONLY) Fill with oil prior to running gearbox. 36 For transport purposes this unit has been supplied with oil in a separate sealed container. 1. Lift off the cover to the 37 operator. 2. Remove the control card and battery so that you can gain access to the filler plug. 38 3. Unscrew the cap and pour in the oil provided NB. D3 is pre-filled with fluid grease. MAJOR COMPONENTS (
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TABLE 1 RUN (kgF) GATE MASS (kg) START (kgF) D3 25 12 300 D5 60 20 500 16* 16* 500 D5 Light Industrial A5 22 22 500 *LIMITED BY CAPACITY OF PSU 2
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ANTI-LIFT BRACKETS - Guide rollers 39 must ensure that the gate is held vertically. - Fit suitable anti-lift brackets 42. The gap 40 should be <5mm to ensure the gate cannot be lifted off the motor pinion. - For improved safety fit additional support post 41 to prevent gate from falling over if guide rollers fail. 39 3
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D5 A5 100 120 * 100 81 67 80 56 48 60 41 36 40 20 Pull ( kgf ) Time (hrs) A5 with FAN 120 100 80 60 40 20 0 0 Time (hrs) DUTY CYCLE CURVES - FOR THE WARRANTY TO BE VALID, ENSURE THAT THE DUTY CYCLE IS NOT EXCEEDED FOR THE PARTICULAR MOTOR BEING USED. * - DUTY CYCLE IS SUBJECT TO BATTERY AND CHARGER SIZE. 4 Duty Cycle ( % ) 6 8 10 12 14 16 18 20 Duty Cycle ( % ) 22 24 26 28 30 5 15 20 Duty Cycle ( % ) 25 5 30 15 20 25 30
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5 6 7 2 9 11 3 8 10 4 RECOMMENDED INSTALLATION AND † CABLE THICKNESS REQUIREMENTS - LOCAL ISOLATOR - MAINS SUPPLY (min 0.5mm² ‡, 2 CORE + EARTH) - INTERCOM AND STATUS SIGNALING TO HOUSE (0.2mm², *n1 + 6 CORE) - INTERCOM TO GATE STATION (0.2mm², #n2 CORES) - PILLAR LIGHTS (0.5mm², 2 CORE + EARTH) - RADIO RECEIVER (0.2mm², 3 CORE) - PEDESTRIAN KEYSWITCH (0.2mm², 2 CORE) - INFRA RED BEAM (0.2mm², 3 CORE) - FREE EXIT LOOP (1.5mm², multi stranded cable) - FREE EXIT CONTACT (0.2mm², 2 CORE) † For ca
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MECHANICAL MOUNTING DETAILS Option 1 - Bolt down onto concrete plinth - Ensure motor does not protrude into drive-way install baseplate with centre line 250mm off pillar centre. - Position baseplate (43) with centre of single support stud (45) 105mm from edge of gate (46). (This dimension assumes centre line of rack (47) is 20mm from edge of gate). - Using the baseplate as a template mark and drill the 4 mounting holes into the concrete for the four M10 x 95 expansion studs. - Use t
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250mm M10 Nut M10 Washer Use two M12 plated nuts as spacers. M10 x 95 expansion stud C L Existing concrete plinth 7
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250mm 4 43 3 4 43 3 4 47 7 4 46 6 4 45 5 4 44 4 4 44 4 105mm 20mm C L C L 300mm 400mm MECHANICAL MOUNTING DETAILS Option 2 - Set into concrete plinth - Ensure motor does not protrude into drive-way install baseplate with centre line 250mm off pillar centre. - Fasten concrete anchors (44) to the baseplate (43) using the M10x45 bolts provided. Ensure that the bolts are well tightened. - Position baseplate (43) with centre of single support stud (45) 105mm from edge of gate (46). (This di
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46 47 43 PROVISION FOR CABLES - Ensure cables 46 are fitted through base plate 43 before concreting in place. 47 - Remove knock-outs from gearbox to allow for cable entry. - Route cables in front of battery (D3/D5 motors) as shown above. - Seal cable entry holes with silicone sealer. 9 30 mm 350 mm
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54 54 53 52 51 GEARBOX MOUNTING DOWN DETAILS - Leave at least 7mm clearance between the lower gearbox nuts 52 and the baseplate to allow for later adjustment. - Gearbox MUST be firmly located between top & bottom nuts and washers 54 as shown at 51 . Use spring washer 53 to lock top nut in place. - Slide gearbox forwards or backwards to give ±8mm clearance between front of pinion and edge of gate. 10 7 mm
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55 ±300 mm 56 57 MOUNTING RACK - Attach steel rack to gate using 25x25x2mm angle brackets 55 . Distance between centerline of rack and edge of gate should be 20mm (see ) 56 . - For best results support rack every 300mm. 57 - Rack must be mounted level with a 2 - 3mm clearance . USEFUL TIP l Raise gearbox by an additional 3mm. l Put gearbox into manual mode (see........ 37 on page 22) l Mesh rack and pinion fully and mount rack. Slide gate backwards and forwards ensuring that
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59 58 200 - 300mm LEVEL 200mm 60 MOUNTING RACK CONTINUED - A simple way of ensuring correct pitch spacing when joining steel rack is to clamp a small offcut 58 between the two pieces. 59 - Check that weld does not foul with meshing surfaces. 60 - If RAZ ™ rack is used, then start installing from the right hand side of the gate working towards the LHS. Use fastening screws e.g. “TEK” screws at least every 200mm. 12
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65 IDLER PULLEYS 64 >100mm 63 >100mm 62 61 INSTALLING CHAIN DRIVE SYSTEMS - Weld rear anchor plate 61 onto gate such that centre line of tensioner pin 62 is in line with top of the shaft on the idler pulley 64 . Allow at least 100mm between idler pulleys and anchor brackets. 63 61 - Align fixed anchor bracket as for . 65 - Ensure chain direction over sprocket is as shown (see ). 13
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6mm 13mm <15kgF SETTING MECHANICAL CLUTCH (A5 ONLY) - Isolate MAINS POWER. - Remove fan from motor to expose the motor shaft (where applicable). Ensure fan has stopped turning. - Lock shaft using 13mm spanner and use 6mm allen key to adjust sensitivity - Clockwise to increase force. - Recommended maximum push force should not exceed 15kgF. 14
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MOUNTING CONFIGURATION FOR STEEL RACK BOLT USING WELD 66 FASTENERS MOUNTING PROVIDED BRACKET A PROVIDED TO 68 STEEL RACK ORIGIN MARKER BRACKET 66 GREATER THAN 500mm 66 B 66 C C 13-20mm 68 MOUNTING OF GATE SENSOR - With the gate in the CLOSED position, mount the origin marker (66) a minimum 500mm from the origin sensor (68). (See isometric view (A) or plan view (B) above).Please note this distance will affect the pedestrian opening distance. For minimum pedestrian opening, mount th
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L L N N E E L N E CP81 CP80 CP80 PSU1 M1 M2 M3 L N E LIGHT COM 17 15 M M 1 12 2 16 16 15 15 E E E E N N N N L L L L 75 13 13 21 76 14 18 20 BATT - BATT + 19 19 13 21 17 * POWER WIRING (SEE PAGE 15 FOR SIGNAL WIRING) - 220V AC MOTOR WITH STARTING CAPACITOR - 220V AC, 1Ø, MAINS SUPPLY FOR CP84E / CP83E USING REMOVABLE CONNECTORS - CP83E POWER SUPPLY TRANSFORMER (A5 MODEL ONLY) - 220V AC PILLAR LIGHT (NOT AVAILABLE ON CP84XTE PSU) - 12V DC MOTOR - 12V DC LEAD ACID BATTERY (Amp/HOUR RATING TO SUI
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CP80 / CP81 NEG 12V 22 N/O COM NEG 12V 23 12V NEG 24 COM N/C 25 26 27 28 29 SIGNAL WIRING (CP80 AND CP81) - RADIO RECEIVER (OR OTHER TRIGGER e.g. INTERCOM) - INFRA RED BEAM TRANSMITTER - INFRA RED BEAM RECEIVER (N/C CONTACT) - FREE EXIT TRIGGER (N/O CONTACT) † - REMOTE STATUS LED (MAX 3 IN PARALLEL) - PEDESTRIAN TRIGGER (N/O CONTACT) - HOLIDAY LOCKOUT CONTROL (N/C LATCHING CONTACT) - REMOTE PILLAR LIGHT CONTROL (N/O CONTACT) = LED INDICATORS ON P.C.B. SHOWING STATUS OF INPUT SIGNALS † = USE MUL
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31 34 50 E N L 220V AC LNE INPUT 220V AC OUTPUT 49 TO CP80/CP81 PCB "DC IN” 43 48 RECOMMENDED LIGHTNING PROTECTION - For optimum lightning protection ensure earth cable from charger/PSU unit 34 is adequately earthed. 49 - Use ring lug to bond to baseplate mounting stud. 43 48 - For additional protection bond baseplate to earth spike . - In event of damage to charger/PSU unit 34 disconnect quick release link 50 and push-on connector on controller. 18
