Centurion D10 Turbo User Manual

D10 and D10 Turbo Installation Manual

TM

TM

INDUSTRIAL SLIDING GATE OPERATOR

CompanyProfile

1986	1990	1995	1999	Centurion Systems
				today

In-house			Manufacture to
R & D			international
development			quality standard
team			ISO 9001:2008

100%	Competent
testing of	after-sales
products	technical support
	from 07h00 - 18h00
	Monday to Friday

Sales and support throughout Southern Africa and over 50 countries worldwide

Centurion Systems (Pty) Ltd reserves the right to make changes to the products described in this manual without notice and without obligation of Centurion Systems (Pty) Ltd to notify any persons of any such revisions or changes. Additionally, Centurion Systems (Pty) Ltd makes no representations or warranties with respect to this manual.

No part of this document may be copied, stored in a retrieval system or transmitted in any form or by any means electronic, mechanical, optical or photographic, without the express prior written consent of Centurion Systems (Pty) Ltd.

Contents

Mechanical Setup

Electrical Setup

Commissioning and Handover

IMPORTANT SAFETY INSTRUCTIONS

1.Declaration of Conformity

2.General Description

Lightning Protection

Theft Protection

3.Specifications

Physical Dimensions

Technical Specifications

Fuse Protection

4.Icons used in this booklet

5.Product Identification

6.Required Tools and Equipment

7.Preparation of Site

General considerations for the installations

Endstops

Guide-rollers and anti-lift bracket

Starting and running forces

8.Cabling Requirements

9.Lubrication

10.Operator Installation

11.Electrical Setup

12.Wiring Diagram for Closing Safety Beam

13.Wiring Diagram For opening Safety Beam

14.Wiring Diagram for External Radio Receiver and Loop Detector

15.Wiring Diagram for other Inputs

16.Mains Supply, Battery, Charger and Pillar Light Connections

17.Earthing for Effective Lightning Protection

18.Commissioning the System

Setting the gate limits

19.How to set up additional features on the D10/D10 TURBO controller

20.Menu Navigation Map

21.Controller Features

22.Factory Defaults Schedule

23.Description of Terminal Functions

24.Diagnostics

page 1 page 2 page 2

page 3

page 5 page 6 page 6 page 7 page 8 page 8 page 8 page 9 page 9

page 10 page 11 page 12 page 12 page 13 page 14 page 15 page 16 page 17 page 18 page 28 page 29 page 30 page 31 page 32 page 33 page 34 page 35 page 35 page 36 page 37 page 40 page 53 page 55 page 58

	Diagnostic LEDs	page 58
	Gate Status LED	page 58
	LCD Display	page 59
	Buzzer Feedback	page 60
25. Fault-finders Guide		page 61
26. Manual Operation		page 65
	Manual release operation	page 65
	Manual release latching	page 65
27. Installation Handover		page 66

Mechanical Setup

These abbreviated instructions are for the experienced installer who needs a checklist to get a standard installation up and running in the minimum of time.

Detailed installation features and functions are referred to later in this manual.

Heed necessary site considerations	page 12
Check cabling requirements	page 15
Gather required tools and equipment	page 11
Secure foundation plate	page 20
Add oil to gearbox	page 16
Mount gearbox	page 21
Mount rack	page 23
Mount origin marker	page 26

Apply warning decals

page 27

Electrical Setup

step 10

Connect all wiring

Commissioning

and Handover

step 11

Set gate end-of-travel limits

step 12

step 13

Set additional features via the menus, if required

Carry out professional handover to client

IMPORTANT

Safety Instructions

ATTENTION

To ensure the safety of people, it is important that you read all the following instructions. Incorrect installation or incorrect use of the product could cause serious harm to people.

The installer, being either professional or DIY, is the last person on the site who can ensure that the operator is safely installed, and that the whole system

can be operated safely.

Warnings for the installer

CAREFULLY READ AND FOLLOW ALL INSTRUCTIONS before beginning to install the product.

All installation, repair, and service work to this product must be carried out by a suitably qualified person

Do not activate your gate opener unless you can see it and can determine that its area of travel is clear of people, pets, or other obstructions

NO ONE MAY CROSS THE PATH OF A MOVING GATE.

Always keep people and objects away from the gate and its area of travel

NEVER LET CHILDREN OPERATE OR PLAY WITH THE GATE CONTROLS

Secure all easily accessed gate opener controls in order to prevent unauthorized use of the gate

Do not in any way modify the components of the automated system

Do not install the equipment in an explosive atmosphere: the presence of flammable gasses or fumes is a serious danger to safety

Before attempting any work on the system, cut electrical power to the operator and disconnect the batteries

The mains power supply of the automated system must be fitted with an all-pole switch with contact opening distance of 3mm or greater. Use of a 5A thermal breaker with allpole circuit break is recommended

Make sure that an earth leakage circuit breaker with a threshold of 30mA is fitted upstream of the system

Never short circuit the battery and do not try to recharge the batteries with power supply units other than that supplied with the product, or by Centurion Systems

Make sure that the earthing system is correctly constructed, and that all metal parts of the system are suitably earthed

Safety devices must be fitted to the installation to guard against mechanical movement risks, such as crushing, dragging and shearing

It is recommended that at least one warning indicator light be fitted to every system

Always fit the warning signs visibly to the inside and outside of the gate

The installer must explain and demonstrate the manual operation of the gate in case of an emergency, and must hand the User Guide over to the user

Explain these safety instructions to all persons authorized to use this gate, and be sure that they understand the hazards associated with automated gates

Do not leave packing materials (plastic, polystyrene, etc.) within reach of children as such materials are potential sources of danger

Dispose of all waste products like packaging materials, worn out batteries, etc. according to local regulations

Always check the obstruction detection system, and safety devices for correct operation

Centurion Systems does not accept any liability caused by improper use of the product, or for use other than that for which the automated system was intended

This product was designed and built strictly for the use indicated in this documentation. Any other use, not expressly indicated here, could compromise the service life/operation of the product and/or be a source of danger

Everything not expressly specified in these instructions is not permitted.

page 4

1. Declaration of Conformity

Manufacturer:

Centurion Systems (Pty) Ltd.

Unit 13 Production Park

Intersection Newmarket Road & Epsom Avenue

North Riding

Gauteng

South Africa

Declares that the product:

Product name: D10/D10 Turbo Sliding gate operator

Conforms with the following specifications:

Safety:	SANS 60335-1:2007
	IEC 60335-1:2006
Emissions:	CISPR 11 CLASS A - Radiated and conducted Interference field
	strength (emission tests) – 150KHz TO 6GHz
Immunity:	IEC 61000-4-2 – Electrostatic discharge
	IEC 61000-4-3	– Radiated immunity – 80MHz TO 1000MHz
	IEC 61000-4-4	– Electrical fast transients/burst
	IEC 61000-4-5	– Surges
	IEC 61000-4-6	– Conducted immunity – 150KHz TO 80MHz

IEC 61000-4-11– Voltage dips and interruption

Standard to which conformity is declared:

IEC 60335-1:2006	Safety
IEC 61000-6-4:2006	Emissions
IEC 61000-6-2:2005	Immunity

Signed at North Riding, South Africa on April 14, 2010

Ian Rozowsky

Research & Development Director.

page 5

2. General Description

The D10 is a heavy duty sliding gate operator designed to open and close industrial sliding gates weighing up to 1000Kg.

The D10 Turbo is perfectly suited for sites with lighter gates requiring a high number of operations per day, and can reach almost double the speed of the standard D10. However, it is not recommended for gates weighing more than 240kg, as the inertia generated by heavier loads might prove detrimental to the gearbox at such high speeds.

A die cast aluminium gearbox, coupled to a powerful 24V DC motor and switch-mode charger, make the D10/D10 Turbo the automatic choice for townhouse complexes and office parks. Gate travel limits are managed by an opto-electronic system, comprising a gate-mounted origin magnet and an internal rotary encoder. This system yields precise and repeatable control over gate position. The gearbox of the D10 Turbo utilises a “true” or “full involute” gear instead of a helical gear, which means that there is a larger contact area with the worm shaft, ensuring much greater load bearing capabilities. The standard D10 uses a 34 tooth internal gear and a 17 tooth output pinion, whereas the D10 Turbo uses a 22 tooth internal gear and a 20 tooth output pinion.

Advanced features of the D10/D10 Turbo logic controller include:

Interactive graphical user interface via a backlit LCD display

Automated setup of gate endpoints (limits)

Fail-safe collision detection and auto reverse (adjustable sensitivity)

Smooth, adjustable start/stop (ramp-up/ramp-down)

Multiple operational modes

Selectable, adjustable Autoclosing

Pedestrian (partial) opening

Positive Close Mode

Independent safety inputs for opening and closing beams

Automatic beam test for both opening and closing beams

Advanced beam alarm functions

Advanced lightning/surge protection

Timed courtesy light output

Multiple pre-flashing modes

Independently adjustable motor speed in both opening and closing directions

Onboard CENTURION rolling code (KeeloqTM encryption) radio receiver with full channel mapping capability (limited to 500 buttons)

Onboard ChronoGuard (patent pending) timer for timed activation of physical inputs or outputs and time-barring of physical inputs or outputs and remote controls

Lightning Protection

The electronic controller utilises the same proven surge protection philosophy that is used in all CENTURION products. While this does not guarantee that the unit will not be damaged in the event of a lightning strike or power surge, it greatly reduces the likelihood of such damage occurring. The earth return for the surge protection is provided via the mains power supply earth.

page 6

In order to ensure that the surge protection is effective, it is essential that the unit is properly earthed.

Theft Protection

While care has been taken in the design of the D10/D10 Turbo to prevent unauthorized removal (theft) of the unit, an optional steel theft-resistant cage is also available for added peace of mind.

page 7

3. Specifications

Physical Dimensions

384mm

67mm

300mm

234mm

340mm (theft-resistant cage)

FIGURE 1. OVERALL DIMENSIONS

Technical Specifications

	D10	D10 Turbo
Input voltage	220V AC ± 10%, 50Hz	220V AC +/- 10% @ 50Hz
Motor voltage	24V DC	24V DC
Motor power supply	Battery driven (standard	Battery driven (standard
	capacity - 2 x 7Ah)	capacity - 2 x 7Ah)
Battery charger	2A @ 27.5V	2A @ 27.5V
Current consumption (mains)	170mA	170mA
Current consumption (motor at rated load)	4A	8A
Operator push force - starting	40kgf	20kgf
Operator push force - rated	30kgf	15kgf
Gate mass - maximum	1000kg	240kg
Gate length - maximum	20m	50m
Gate speed (varies with load)	22-26 m/min	40-50m/min
Manual override	Lockable lever with	Lockable lever with
	key release	key release
Maximum numbers of operations per day	750	750
Duty cycle - mains present	45%	25%
Operations in standby with 7Ah battery
half day	87	58
full day	69	37

page 8

Operations in standby with 35Ah battery	D10	D10 Turbo
		372
half day	507
full day	489	351
Collision sensing	Electronic	Electronic
Operating temperature range	-15°C to +50°C	-15°C to 50°C
Onboard receiver type	CENTURION rolling code	CENTURION rolling code
	(KeeloqTM encryption)	(Keeloq™ encryption),
	multichannel	multichannel
Receiver code storage capacity	500 transmitter buttons	500 transmitter buttons
Receiver frequency	433MHz	433MHz
Degree of protection	IP54	IP54
Mass of unit packed (standard kit,	13kg	13kg
excl. rack and battery
Packing dimensions (standard kit,	350mm long x 290mm	350mm long x 290mm wide
excl. rack and battery)	wide x 490mm high	x 490mm high

Based on 6m gate, no accessories fitted, such as infrared beams

Fuse Protection

The following protection fuses are provided on the system:

Item	Type	Rating
Main controller
Motor circuit	Automotive fuse ATO (25 x 7 mm) 30A
Light circuit	5 x 20mm	3A fast blow
Auxiliary supply	Electronic limit	300mA
Charger
Mains input	5 x 20mm	3A fast blow*

*Not user serviceable

4.Icons used in this manual

This icon indicates tips and other information that could be useful during the installation

This icon denotes variations and other aspects that should be considered during installation

This icon indicates warning, caution or attention! Please take special note of critical aspects that MUST be adhered to in order to prevent injury

page 9

5. Product Identification

		FIGURE 2. PRODUCT IDENTIFICATION
1.	D10/D10 Turbo controller
2.	D10/D10 Turbo charger	Gate-mounted origin marker
3.	8.
	Motor fuse (15A ATO)	Origin sensor
4.	9.
	Courtesy light fuse (3A F/B)	Origin marker bracket
5.	10.
	Manual release handle	Encoder sensor
6.	11.
	Lock cover	Lower cover
7.	12.
	2 x 12V 7.2A/Hr battery	Foundation plate
	13.

page 10

6.Required Tools and Equipment

Pull scale – 50kg

Spanner – 17mm; 10mm

Screwdriver – 3.5mm flat

Allen key – 6mm; 4mm

Crimping tool and pin lugs

Side cutters

Hacksaw

Spirit level

Measuring tape

If casting foundation plate into concrete:

Pick

Spade

If bolting foundation plate onto existing plinth:

Drilling equipment

Masonry bits to suit rawlbolts being used

If welding foundation plate and/or rack to gate:

Welding equipment

G Clamp, 6 inch x 2

If fastening rack to gate:

Drilling equipment

TEK screw socket

page 11

7. Preparation of Site

General considerations for the installation

1.Always recommend the fitment of additional safety equipment such as safety edges and safety beams, for additional protection against entrapment or other mechanical risks

2.Since the D10 Turbo operates at exceptionally high speeds, it is mandatory to install the following additional safety equipment in order to ensure the safest possible installation:

a)Opening safety beams which will prevent the gate from moving should anyone be in the path of the gate while OPENING. This provides an effective means of safeguarding against dragging.

b)Closing safety beams which will prevent the gate from moving should anyone be in the path of the gate while CLOSING. This is important to prevent being crushed by the gate while in motion.

c)Passive Sensitive Edge to help absorb the kinetic energy of the gate in the event of a collision, and provides additional time for the inherent electronic anti-crushing technology of the operator to react.

3.The IRBOC option must be invoked so that the gate will immediately reverse direction, in the event of a collision, regardless of whether it is in the opening or closing cycle

4.Safety beams are installed on either side of the driveway, as shown in Figure 3

5.Sensitive edges are typically installed on all shearing edges of the gate, as shown in Figure 3

Passive

Infrared sensitive edge

Infrared

FIGURE 3. INFRARED BEAMS AND PASSIVE SENSITIVE EDGE

6.Check that no pipes or electrical cables are in the way of the intended installation

7.Check that enough space is available for the gate operator with the gate in the required open position

8.Check for loose sandy soil if installing foundations, as the soil condition may require a larger foundation

page 12

Install the gate operator only if:

1.It will not pose a hazard to the public

2.There is sufficient clearance to a roadway and/or public thoroughfares

3.The installation will meet all municipal and/or local authority requirements once completed

4.The gate mass, length and application is within the operator specifications

5.The gate is in good working order, meaning:

a)That it moves freely

b)Does not move on its own if left in any position

c)It can be installed to have sufficient clearance between moving parts when opening and closing to reduce the risk of personal injury and entrapment

6.Pushbuttons or keyswitches, when required, can be positioned so that the gate is in line of sight of the operator

Endstops

Fit endstops capable of stopping the gate at rated speed. Refer to specifications at the beginning of this manual for the operating speed

Make H>h to ensure gate will not jump over endstop

Endstop	Endstop
	Ø16mm

FIGURE 4. FITTING ENDSTOPS

WARNING!

Endstops are mandatory and must be fitted to prevent death or accidental injury should the gate overrun its limits

page 13

Guide-rollers and anti-lift brackets

1.Guide-rollers must ensure that the gate is held vertically

2.For improved safety, fit additional support post to prevent gate from falling over if guide-rollers fail

3.To prevent unauthorised access fit anti-lift brackets as shown

4.The gap between the anti-lift bracket and the gate must be less than 5mm

Ensure that the gate cannot be lifted off the motor pinion with the anti-lift bracket fitted

GAP<5mm GAP<5mm

GAP<5mm GAP<5mm

Guide-rollers

Additional support post

FIGURE 5. FITTING GUIDE-ROLLERS

page 14

Starting and running forces

1.Test the starting force of the gate as per the diagram. Use a pull scale to determine the maximum amount of pull force required to get the gate moving

2.Determine the running force of the gate by continuing to pull on the scale with just sufficient force to keep it running and read off the maximum value in kgf shown on the scale

3.Where possible determine the gate mass

4.The CENTURION warranty will be void if the pull force and or gate mass, exceed the operator specification as below:

D10

Starting force - 40kgf

Running (rated) force - 30kgf

Maximum gate mass - 1000kg

D10 Turbo

Starting force – 20kgf

Running (rated) force – 15kgf

Maximum gate mass – 240kg

Pull scale

FIGURE 6. STARTING AND RUNNING FORCES

page 15

8. Cabling Requirements

Mains isolator switch

Todwelling

	FIGURE 7. CABLING REQUIREMENTS
Legend
1.	220V AC mains cable via double pole mains isolator switch (3 core LNE 1.5mm2 SWA)
2.	Optional intercom cable from motor to dwelling (n1 + 6 core 0.5mm2 multi-stranded)

3.Optional intercom cable from motor to entry panel (n2 0.5mm2 multi-stranded)

4.Optional but recommended infrared safety beams (3 core 0.5mm2 multi-stranded)

5.Optional access control device (3 core 0.5mm2 multi-stranded)

6a. Optional pedestrian keyswitch (2 core 0.5mm2 multi-stranded) OR

6b. Optional keypad (3 core 0.5mm2 multi-stranded)

7.Optional external radio receiver (3 core 0.5mm2 multi-stranded)

8.Optional pillar lights (3 core LNE SWA, size according to power requirements)

9.Optional ground loop for free exit (1core 0.5mm2 multi stranded – silicone coated)

n1 = number of cores required by intercom

n2 = number of cores required by intercom

Possibly increase cable thickness if pillar lights are installed

Type of cable must adhere to municipal bylaws but typically SWA (steel wire armoured) cable is recommended. The armouring provides excellent screening, which gives better protection against lightning – earth one end of the screening)

Allows for all features such as pedestrian opening, status LED etc., to be operated from the intercom handset inside the dwelling. Number of cores and type of cable could vary depending on brand of access control system being used

For optimum range, an external receiver can be mounted on the wall Consult manufacturer of loop detector for specific details

page 16

9. Lubrication

Do not attempt to run the operator without first filling the gearbox with lubricant

The internal gearset of the D10/D10 Turbo is lubricated by means of an oil bath

In order to prevent possible leakage during shipping, the unit is shipped with no oil inside the gearbox. A bottle containing 80ml of a special synthetic oil is included with the product, and this must be introduced before operating the product. (Product code: OIL80ML0X0/H)

It is more convenient to introduce oil before bolting the unit down, as shown in Figure 9.

The D10/D10 Turbo does not require routine oil changes. However in the event of the unit losing oil due to stripping down or mechanical damage, the correct replacement oil is Castrol SAF X0 75W-90 synthetic final drive lubricant. If the gearbox is bolted down in the horizontal position during filling, the correct level is reached when oil begins to spill from the filler hole.

FIGURE 8. LUBRICATION

Step 1: Remove dipstick from gearbox

Step 2: Cut the tip off the nozzle which will allow for the oil to pass through the nozzle;unscrew the oil bottle cap; remove the seal from beneath the oil

bottle cap;replace the oil bottle cap onto the bottle and, attach the extension tube to the nozzle

Step 3: Fill the gearbox with the oil provided

Please ensure that you only use the following oil as qualified by CENTURION: Castrol SAF-XO 75w-90 Synthetic Final Drive Lubricant.

CENTURION re-order code OIL80ML0X0/H.

page 17

10. Operator Installation

Locate operator position

1.To ensure operator does not protrude into driveway, install base plate at least flush with the driveway entrance

2.Determine a suitable position and vertical height for the operator by considering Figures 9 and 10.

3.It is typical to mount the rack above the pinion as shown in Figures 9A and 10A for each type of rack considered. However, in each case, Figures 8B and 9B shows the rack mounted underneath.

If there is space to mount the rack underneath without fouling the ground as the gate moves, the following are the pros and cons:

Pros

The rack is more hidden from view

It provides a very effective anti-lift bracket

It ensures that as the gate beds in, the rack does not drop onto the pinion loading the operator unnecessarily

Cons

Rack teeth face up vertically potentially collecting dirt

Custom bracket

With careful selection of the rack configuration, and operator vertical height, mounting of the rack could in some cases be greatly simplified.

If a theft-resistant cage is required, be sure to leave enough clearance from pillars, etc.

(Recommended to allow for adjustment)
	92	156*	5
Foundation	43 - 53
plate
Flat bar welded to			Raised
foundation plate and rail			foundation	43 - 53
* Includes 3mm clearance required between rack and pinion
FIGURE 9A STEEL RACK, ABOVE PINION			FIGURE 9B STEEL RACK, BELOW PINION

page 18