gr linear gate system

GR LINEAR GATE SYSTEM
Made in Italy
Electronic control unit for 24V gate operators with encoder.
Updated: October 2013
Proudly Made In Italy
TABLE OF CONTENTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13. Advance Programming
13.1 Disable soft stop
13.2 Increase starting torque
13.3 7-day timer
13.4 Safety reversing devices (on during opening)
13.5 Safety entrapment (always on)
13.6 Courtesy lights
13.7 Warning light
13.8 Deactivate leaf delay
13.9 Electric lock on during closing cycle
13.10 Reset system to default
14. Solar notes
15. Radio receiver & keypad programming
16. Maintenance
17. Technical Data
18. Parts List
Main features
Safety info
Control box & accessories
Mechanical installation
Positive stop installation
Preliminary wiring diagram
Operator motor direction wiring
Control cabinet images
Main wiring diagram
Block Wiring Layout
Gate swing direction
Preliminary programming
12.1 Programming single gate
12.2 Programming for dual gates
12.3 Addition basic programming
12.4 Auto close timer
12.5 Activating auto close timer
12.6 Resetting to manual operation
12.7 Torque adjustment
1. MAIN FEATURES
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European quality design and construction
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Operator is all aluminum construction with steel and bronze gears
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Solar friendly
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Optional battery backup
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Large heavy duty control cabinet fits all accessories
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Soft stop function
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Encoder used to control gate position instead of limit switches
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Auto close timer or manual operation
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Adjustable torque control for safe operation
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Warning light output
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Security & path light output
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Optional loop detector mother board to facilitate fast and easy loop installation

Mag lock output

7 Day timer input

Gate status LED’s

Entrapment device input
Page 1
2. SAFETY INFO
CAUTION
Before installation, please read this manual thoroughly and carefully in order to properly install and program your new
gate operator. Be sure to pick a suitable mounting location for the control cabinet Be sure to disconnect power during
installation and maintenance. Disconnect power from any accessories as well when servicing.
! Safety Installation Information!
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Safety needs to be considered for aspects of the installation.
Gate operators can create high levels of force that can crush and trap people.
Safety devices such as photo eyes, pressure sensing edges, wheel guards, roller
guards are necessary,
The installation should be inspected and any sharp edges should be removed.
This operator is intended for use on gates for vehicle passage. Pedestrians should
not be using an automated driveway gate for passage. A separate walk through
gate is required.
A minimum of 2 warning signs need to be placed on both sides of the gate.
Gate controls need to be placed at least 6 feet away from the gate.
Gate activating devices should be installed a minimum of 10’ away from gate.
The force (torque) of the operator should be adjusted so that there is no more
than 20lbs of force at the leading edge of the gate. This can be tested with a fish
scale.
The gate should be installed with enough clearance from structures so as to not
cause entrapment zones. Areas that can trap people such as between a fence and
an opening gate need safety devices such as photo eyes.
The speed limit is 5 miles per hour through the gate. Post speed limit and install
speed bumps as needed.
WARNING
To reduce the risk of death or injury follow these instructions
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Never allow children to play on or near gate, gate operator, or gate controls. Do
not ride on moving gate.
Gate is for vehicles only. Do not walk through an automated gate.
Periodically test and adjust the force of the gate.
Page 2
3. CONTROL BOX WITH INCLUDED AND OPTIONAL ACCESSORIES GR300 & 400 Operators
Page 3
4. MECHANICAL INTALLATION
Operators come as left and right units. Make sure that you have the correct operator installed. The slanted side
should be facing out as pictured below.
MANUAL RELEASE:
To manually lock or unlock (release) the gate operator with the supplied hex key (See FIG 1)
1 - Remove the protective cover 2 - Insert the hex key 3 - Turn the key counter clockwise to release the operator and
clockwise to lock it.
FIG 1
COUNTER CLOCKWISE:
RELEASED
CLOCKWISE:
LOCKED
INSTALLATION
B
FIG 2
D
A
A – Post bracket
B – Gate bracket
D – Piston rod
C – Manual Release
C
Bracket B
Bracket A
Page 4
INSTALLATION
For a proper installation of the GR400-600 gate operator, carefully
follow the instructions below.
6 - With the gate in the closed position and operator released, manually
slide shaft “D” outward until the shaft D reaches the end of its stroke.
7 - Manually turn shaft “D” back inward 1 full turn (360º).
1 - Make sure that the gate is level.
2 - Install mechanical limit stops (FIG 8),
3- Attach the post bracket “A” (FIG 2) on the hinge post of the
driveway gate using the dimensions provided in TABLE 1 below.
NOTE: You may fasten operator brackets with screws, bolts, or
welding depending on surface. It is recommended to weld brackets or
through bolt them when fastening to steel.
FIG 6
4 - Install brackets so gate operator end is approximately 1 degree
(about 5/8” or 15mm) below level to facilitate water runoff (FIG 3).
360°
FIG 3
8 - Place gate bracket “B” in the hole at the end of the shaft “D” using the
pin and hex screw. Fasten it to the closed gate leaf taking into account
the angle illustrated in FIG 3.
5 - Install the gate operator to the post bracket “A” (FIG 2) and secure
it using the supplied pin & hex screw.
NOTE: Be sure to install swivel pin with female threads facing down
on both ends of operator (Fig 4) to allow future removal of operator.
FIG 4
9- Duplicate the procedure on the second leaf if installing a dual gate.
10 – Wire operators using basic wiring (FIG 9),
11 - After system is tested using basic wiring, proceed to add
accessories one at a time using the main wiring diagram (FIG 11)
12 - Place the cover on the arm release key hole “C” (FIG 7)
FIG 7
FIG 5
TABLE 1
MOTOR
SWING 95 °
W
GR400
GR600
1122mm
44 3/16”
1532mm
60 5/16”
SWING 120 °
X
Y
Z
W
X
Y
Z
145mm 5
3/4 ”
145mm 5
3/4”
478mm 18
13/16”
1122mm
44 3/16”
170mm 6
11/16”
110mm 4
5/16”
478mm 18
13/16”
280mm 11”
280mm 11”
678mm 26
11/16”
1532mm
60 5/16”
310mm
12 3/16”
120mm 4
3/4”
678mm 26
11/16”
Page 5
5. POSITIVE STOPS INSTALLATION:
Positive stops are required. A simple piece of angle iron mounted on the passive post will suffice on a single gate. Dual
gates require positive stops mounted on the hinge side post. Positive stop kits are available at your dealer.
FIG 8
Page 6
6. PRELIMINARY WIRING DIAGRAM:
Start by connecting only the gate operators, and the main power. Add accessories in stages, and testing each one
to make sure it works. Use only basic programming to start with.
FIG 9
See FIG 10 for Operator Wiring Page 7
7. OPERATOR MOTOR DIRECTION WIRING:
NOTE: Mechanical positive Stop(s) are required.
FIG 10
Page 8
8. CONTROL BOX LAYOUT
Page 9
9. MAIN WIRING DIAGRAM
FIG 11
Page 10
10. BLOCK WIRING LAYOUT (showing safety devices) Page 11
11 GATE SWING DIRECTION:
1 - Confirm that power is turned off and set dipswitches 1-2-3-4 to off position.
2 - Disengage the operators and set the gate leafs to the halfway open position, and then reengage the operators.
3 - Turn on power supply, LEDs L3, L4 and L9 should illuminate (LED’s 5&6 may or may not be illuminated) If LED’s
fail to come on, power down the system and check all the wiring connections including 110VAC, power transformer,
batteries, solar panels, fuses, etc… Then turn the power on again.
4 - Press BP1, the motors should start closing (first M2 then M1 in dual operator installations).
5 - If either of the operators move towards the open position when you press BP1, disconnect the power and reverse
the wiring for that motor (terminals 20 & 21 for M1, 22 & 23 for M2). Disengage the operators and return the gates to
the halfway position reengage the operators and turn the power on again.
6 - In dual gate systems motor M2 moves first. If M1 moves first, swap the motor and encoder terminals.
7 - Repeat step 4. To test the direction.
8 - Once the swing direction has been set. Turn off the power, disengage the operators and move them to the desired
open position. Reengage the operators and turn the power back on.
12. PRELIMINARY PROGRAMMING. More advanced features are at end of this section.
12.1 PROGRAMMING FOR SINGLE GATE: (See operator wiring diagram page)
1 - Disengage the operator; place gate in the desired open position and the reengage the motor.
2 - Place dipswitch 1 in the ON position and the L9 LED should start flashing.
3 – Remove power by lifting the 28-29-30 terminal block for 3sec. (until the LED’s entire are off) and then restore
power.
4 - Press BP1 and the operator will begin programming the open and closed position.
5 – During the closing cycle, press the BP1 button about 30 degrees before closing to set the beginning of the
soft stop phase of the cycle. If you do not wish to use soft stop, do not press the button.
6 – You have now finished programming the open and close positions of the operator.
7 – Reset all dipswitches to the off position.
M1
BP-1
INITIAL TESTING:
NOTE: Operator pushes against stops on first activation to set limits.
Press BP1. The gate operator should run through its cycle and you will be able to determine if it has correctly
programmed the open and close positions as well as the soft stop feature.
12.2 PROGRAMMING FOR DUAL GATES (See operator wiring diagram page)
1 – Disengage both operators and place them in the desired open position and then reengage the operators.
2 – Place dipswitch 1 in the ON position and the L9 LED should start flashing.
3 – Remove power for 3 sec. (until the LED’s are entirely off) and then restore power.
4 - Press BP1 and the operators will begin programming the open and closed position. Motor 2 should close first and
stop automatically on the positive stop, followed by Motor 1.
5 – During the closing cycle, press the BP1 button about 30 degrees (approximately 24”) before closing to set the
beginning of the soft stop phase of the cycle for gate motor 2. Press BP1 again to set gate motor 1 soft stop when it
reaches 30 degrees. If you do not wish to use soft stop, do not press the button.
6 – You have now finished programming the open and close positions of the operators. The leaf delay between the
first and second panel will be set automatically so that they do not overlap.
7 – Reset all dipswitches to the off position.
M1
M2
M1
BP1
Page 12
M2
INITIAL TESTING:
NOTE: Operator pushes against stops on first activation to set limits.
Press BP1. The gate operators should run through its cycle and you will be able to determine if it has correctly
programmed the open and close positions as well as the soft stop feature.
12.3 ADDITIONAL PROGRAMMING:
Prior to completing any additional programming, you must make sure that the gate is in the closed position and the
LED no.9 is solidly lit. If the light is flickering you will need to disconnect and reconnect the power supply.
12.4 AUTO CLOSE TIMER
After completing the initial programming the operators will function in Manual mode. In this state it will require one
input to open the gate, a second input during the gates movement will stop the gate, and a third input will cause the
gate to close. The gate will also close if it is in the fully open position when it receives an input. If you would like to
have the gate close automatically after a set period of time, follow the below instructions.
12.5 Activating and setting auto close timer:
1 – Place dipswitch 1 & 4 in the ON position.
2 – L9 Led will begin to flash.
3 – Press BP1 and the L9 LED will begin to flash quicker. This is the beginning of the timer setting.
4 – After reaching the desired pause time (up to 4 minutes) press BP1 again and the L9 LED will flash at the normal
rate again. Note: Pause time must be set for 5 seconds or more or it will stay in the manual mode.
5 – Reset the Dipswitches to the OFF position. The auto close timer is now complete.
Note: if BP1 is not pressed the unit will default to the maximum time of 4 minutes.
INSTALL SAFETY DEVICEs SUCH AS A PHOTOEYE, SAFETY EDGE, OR LOOP DETECTOR IF YOU PLAN ON
12.6 Resetting to the manual mode (Turn off timer):
1 – Place Dipswitches 1 and 4 in the ON position.
2 – The L9 Led will begin to flash.
3 – Press BP1 twice in less than 4 seconds
4 – Reset the Dipswitches to the OFF position. Operator is now manual.
11.7 Adjusting operator torque:
Using the potentiometers “POT1 and POT2” (corresponds to each operator), turn clockwise to increase the force
(torque), or counterclockwise to decrease the force.
13. ADVANCED PROGRAMMING AND FEATURES:
13.1 Disabling the soft stop (Enable/disable):
Certain applications can require a traditional operation without the soft stop phase.
- Disconnect the power
- Place Dipswitches 3 and 4 in ON position
- Press and hold BP2
- Restore power
- L9 flickers then becomes steady.
- Release BP2
- Place DIPs 3 and 4 in OFF position
- Re- program the operators (must re-program operators after removing soft stop)
13.2 Increasing starting torque (Use for heavier gates, or windy conditions)
The control board is preset with a lower starting torque. To use the full torque at starting, use below:
- Disconnect the power
- Place all Dipswitches in OFF position
- Press and hold BP1 & BP2
- Restore power
- L9 flickers then becomes steady
- Release BP1 and BP2 and return dip switches to desired positions
- Repeat operation to return to default mode.
Page 13
13.3 Automatic timer operation (optional 7 day timer required)
The use of a timer allows the opening and the closing of the gate for programmed periods in automatic mode (board
must be in automatic mode). Connect the contact of a timer output relay to terminals 3 and 4 of the board. The gate
will function according to the hour programmed on the timer. Gate will remain locked open during the timers open
cycle regardless of any other contact closure. Gate will respond to any inputs when in the closed cycle.
13.4 Safety device (reversing loops, photo eyes, safety edges) Terminals 4 & 7:
Safety on only during the opening cycle, Stops and reverses after about 1 second.
Note: Terminals 4 & 7 need to have a jumper between them if safety device is not utilized.
13.5 Safety entrapment devices (photo eyes) Terminals 4 & 6
Entrapment devices are always on. If device is triggered the gate won’t open.
During opening gate will stop. Gate will remain in stopped position until safety device is cleared.
During closing the gate will stop and reverse to open position.
Note: Terminals 4 & 6 need to have a jumper between them if safety device is not utilized.
13.6 Courtesy light (security and path lights) Terminals 18 & 19
Do not connect any DC low voltage light over 100mA directly to this terminal. It is necessary to use a 12Vdc relay
connected on terminals 18 and 19 for high current DC light or 110V lights powered by external power source. That
light will only remain lit during the open & close cycles unless a time delay relay is added.
13.7 Warning light in automatic mode (enable/disable) terminals 16 and 17
It is possible to leave the warning light on or off (off is default mode) during the opening pause in automatic mode.
The pre-warning of 3 sec. remains with either mode. Warning light will not remain on during hold open mode.
- Disconnect the power
- Place Dipswitch 2 in ON position
- Press & Hold BP 1 & 2
- Restore power
- L9 flickers, and then becomes steady: release BP 1 & 2 and return dip switch 2 on to off position.
- Repeat operation to return to default mode.
Note: terminal 16 & 17 have 24VDC output
12.3 Deactivation of the gate leafs delay (both gates will open at same time)
- Disconnect the board power
- Place Dipswitch 4 in ON position
- Press an hold BP1 and BP2
- Restore power
- L9 flickers, then becomes steady: release BP1 and BP2 and return dip switche 4 to off position.
13.9 Activates the electric lock at the beginning of the closing cycle
- Disconnect the board power
- Place Dipswitch 3 in ON position
- Press and hold BP1 and BP2
- Restore power
- L9 flickers then becomes steady. Release BP1 and BP2 and return dip switche 3 to off position.
13.10 Default System Reset:
- Disconnect the power
- Place Dipswitch 2,3 and 4 in ON position
- Press and hold BP1 and BP2
- Restore power
- L9 flickers then becomes steady.
- Release BP1 and BP2 and return dipswitche 2,3&4 to off position.
Note: The gate open pause time and stroke are not affected by the reset.
Page 14
14. SOLAR NOTES:
When using the solar option it is necessary to keep the current usage low. Accessories such as mag locks and strobe
lights cannot be used. Keypads and loop detectors have to be special low current units. Solar panel size is determined
by location of system and required accessories. Your dealer or installer should be able to help with determining
adequate panel size. A 20 - 30 watt minimum size panel is recommended.
Page 15
15. RADIO REMOTE & KEYPAD PROGRAMMING:
RECEIVER, TRANSMITTER, & KEYPAD QUICK PROGRAMMING
Radio Receiver Wiring Connect the receiver to the board and turn on power
Programming Radio Transmitter:
1 – Open transmitter (Photo 1) to change code by use of dip switches. Leave at least 1 dip switch in the on position.
2 – Press P1 on the receiver (photo 3) - LED turns ON, then OFF, then ON again. Now the receiver is ready to accept
the transmitter (this programs channel 1 and operates relay 1).
3 - Press desired channel button on transmitter. The LED turns off. It is now programmed. To use the second channel
on the receiver press P1 twice and repeat the procedure this time pressing the second channel on the transmitter.
4 – To remove a transmitter or transmitter channel press P2 (photo 3) LED turns on. Press the transmitter channel
you want to remove. LED turns off. It is now removed.
Photo 1
Dip Switches Programming Keypad:
2 – Turn ON the keypad by moving the jumper in ON position (photo2), the keypad makes a BEEP
3 – Press P1 on the receiver (photo 3) - LED turns ON, then OFF, then ON again. Now the receiver is ready to accept
the code.
4 – Press the desired code on the keypad. Use 1-5 digits (1 – 99999)
5 – Press OK button on the keypad
6 – The code is stored, END of programming, receiver LED shuts off.
7 – To remove a keypad code press P2 (photo 3) - LED turns ON. Enter the code you want to remove on the keypad
and press “OK”. The LED turns OFF. It is now removed.
Photo 2
Photo 3
Page 16
JUMPER P1
P2
LED RECEIVER, TRANSMITTER, & KEYPAD HOLD OPEN INSTRUCTIONS
For use only when gate is programmed in auto close mode
Radio Receiver Wiring
Connect receiver as shown above, connecting
both relays in parallel, then turn on power
Programming Radio Transmitter:
1 – Open transmitter (Photo 1) to change code by use of dip switches. Leave at least 1 dip switch in the on position.
2 – Press P1 ONCE on the receiver (photo 4) LED turns ON, then OFF, then ON again. Now the receiver is ready to
accept the transmitter (this programs channel 1 and operates relay 1 as a momentary closure).
3 - Press CHANNEL1 on transmitter (Photo 2). The LED turns off. It is now programmed.
4 To use the SECOND CHANNEL on the receiver for hold open, press P1 4 TIMES and repeat the procedure this time
pressing the CHANNEL 2 on the transmitter. Operation: The gate stays open after pressing channel 2, until channel 2
is pressed again.
5 – To remove a transmitter or transmitter channel, press P2 (photo 4) LED turns on. Press the transmitter channel
you want to remove. LED turns off. It is now removed.
Photo 2
Photo 1
Channel 1
Channel 2
Dip Switches Programming Keypad:
2 – Turn ON the keypad by moving the jumper in ON position (photo3), the keypad makes a BEEP
3 – Press P1 once on the receiver (photo 3) LED turns ON, then OFF, then ON again. Now the receiver is ready to
accept the code.
4 – Press the desired code on the keypad for auto close operation. Use 1-5 digits (1 – 99999)
5 – Press OK button on the keypad
6 – The code is stored, END of programming, receiver LED shuts off. Repeat process to add additional codes.
7 – To add hold open code press P1 4 times on the receiver (photo 4) LED turns ON, then OFF, then ON again. Now
the receiver is ready to accept the hold open code. Repeat process to add additional codes.
8 – The keypad hold open code holds the gate open until the same code is entered again to close the gate.
9 – To remove a keypad code press P2 (photo 4) - LED turns ON. Enter the code you want to remove on the keypad
and press “OK”. The LED turns OFF. It is now removed.
Photo 4
Photo 3
JUMPER P1
Page 17
P2 LED
16. MAINTENANCE:
SCHEDULED MAINTENANCE
FREQUENCY
DONE BY
Photo Eye Lens and Reflector Cleaning
Monthly
User
Clean with damp cloth
Annual Maintenance
Annually
User
Check condition of gate welds and any corrosion.
Grease the hinges. Disconnect the gate operator
and check for the free and easy movement of the
gate. Check to make sure it does not bind
anywhere during a full swing. Check the
movement of the gate operator. Replace any
damaged parts. Grease the operator shaft.
semiannually
Technician
Check the adjustment of the couple as described
in EN 12453 - EN 12445
Annually
Technician
Verify that the dispersion of current is less than
7.5 A
Semiannually
Operator
Make sure safety signage is complete and intact
DESCRIPTION
Check the force adjustment
Monitoring current dispersion
Safety Warnings
OPERATION
17. TECHNICAL DATA: TECHNICAL DATA Maximum length (per leaf)
GR 300
9 feet
Maximum weight (per leaf)
550 pounds
Piston Stroke
11 ¾”
Power
70 W
Power supply
Amperage
Max. Thrust
Operating temperature
Opening time
Thermal protection
Duty Cycle
Lubrication
110VAC/24VDC
0,5 – 5,5 A
1500 N
-13°F +140°F
16 sec
90%
Page 18
GR 400
13 feet
550 pounds
GR 600
16 feet
550 pounds
15 ¾”
23 ½”
70 W
70 W
110VAC/24VDC
0,5 – 5,5 A
1500 N
110VAC/24VDC
0,5 – 5,5 A
1500 N
-13°F +140°F
21 sec
90%
GREASE
-13°F +140°F
31 sec
90%
18. PARTS LIST: PART # QTY CODE DESCRIPTION PART
Q.TY
CODE
1 1 100645 REDUCTION GEAR COVER LF. BLACK 20 1 100764 DESCRIPTION GREY ALUMINIUM TUBE 600mm STROKE 1 1 1 1 100644 100759 REDUCTION GEAR COVER RG. BLACK REDUCTION GEAR COVER LF. GREY 21 22 1 1 100829 100625 PISTON ROD GUIDE SCRAPER RING 1 2 1 1 100758 100647 REDUCTION GEAR COVER RG. GREY MOTOR CASING RG. BLACK 23 24 1 1 100827 100828 PISTON ROD LOCK NUT FEMALE SCREW 2 10 1 1 100761 100650 MOTOR CASING RG. GREY IRREVERSIBLE TOOTH WHEEL 25 26 1 2 100823 100705 10 1 100751 REVERSIBLE TOOTH WHEEL 27 1 100646 11 2 100789 HELASTIC RING E20 27 1 100906 WALL BRACKET GRUB SCREW M14X10 ALUMINIUM PISTON ROD TERMINAL BLACK ALUMINIUM PISTON ROD TERMINAL GREY 12 13 1 2 100709 100658 BEARING 6004 ZZ TOWING BALL 28 29 1 2 100624 100657 ALUMINIUM UNCLAMPING O‐RING 14 15 1 1 100655 100641 UNCLAMPING PIN UNCLAMPING SPRING 30 31 1 2 100825 100654 GATE BRACKET PIN 17 18 1 1 100661 ALUMINIUM LOCK NUT 24V Motor 1600 rpm 32 33 1 1 100218 100707 UNCLAMPING KEY BEARING 6003 ZZ 19 19 1 1 100712 100713 STAINLESS STEEL TUBE 300mm STROKE STAINLESS STEEL TUBE 400mm STROKE 35 36 1 1 100755 100748 UNCLAMPING CAP CABLE PRESS 19 20 1 1 100738 100714 STAINLESS STEEL TUBE 600mm STROKE BLACK ALUMINIUM TUBE 300mm STROKE 37 + 39 37 + 39 1 1 100716 + 100998 100717 + 100998 ENDLESS SCREW 40 + release shaft ENDLESS SCREW 50 + release shaft 20 20 1 1 100762 100715 GREY ALUMINIUM TUBE 300mm STROKE BLACK ALUMINIUM TUBE 400mm STROKE 37 + 39 38 1 4 100740 + 100998 100313 ENDLESS SCREW 70 + release shaft CAP SCREW M5X16 20 20 1 1 100763 100739 GREY ALUMINIUM TUBE 400mm STROKE BLACK ALUMINIUM TUBE 600mm STROKE
Page 19