Cable Gate MAINTENANCE MANUAL - Access Technologies...1 7, 8 & 10 mm ring/open ended spanners Removing various nuts 1 each Side cutters (in good condition) Trimming end of pull-in

Cable Gate

MAINTENANCE MANUAL

Cable Gate Serial Numbers 03360119 Onwards

Distributed by:

Manufactured by

PO Box 1060,

Gwelup DC WA 6018 Telephone: (08) 9246 9923 Facsimile: (08) 9246 9963

Freecall: 1800 003 285

Confidential – Access Technologies (WA) Pty Ltd Cable Gate – Maintenance Manual Copyright © January 2008

i

Revision 1.0 July 2004

As a result of our commitment to product improvement, Access Technologies (WA) Pty Ltd reserves the right to alter at any time the equipment described in this manual.

Whilst every care has been taken in the production of such manuals, no warranty of accuracy or reliability is given in relation to any advice or information contained in this publication and no responsibility for any loss or damage whatsoever arising in any way for any representation, act or omission whether express or implied (including responsibility to any person by reason of negligence) is accepted by Access Technologies (WA) Pty Ltd. or any officer, agent or employee of Access Technologies (WA) Pty Ltd

Copyright © 2008 Access Technologies (WA) Pty Ltd.

This manual is copyright and all rights are reserved. This document may not, in whole or part, be copied, photocopied, reproduced, translated or reduced to any electronic medium or machine-readable form without prior consent, in writing, from Access Technologies (WA) Pty Ltd.


ii

Amendment History

Revision Amendment Description Date

Approved

0.0 First Release for review 14 March 03 Steve Watson 0.1 Elaborate on Description of Pull-in

Cable Replacement 2 April 03 Steve Watson

1.0 Revised to reflect second production batch

15 July 2004

1.1 ClearFaults button and rotary switch software recovery

28 April 2005

Frank Spaapen


iii

Table of Contents

SECTION 1 - TOOLS AND EQUIPMENT .............................................................................. 1 1.1 REQUIRED TOOLS ..................................................................................................... 2

SECTION 2 - CABLE GATE DIAGRAMS .............................................................................. 3 2.1 EXTERNAL CABLE GATE COMPONENTS...................................................................... 4 2.2 MAIN OPERATING MODULE........................................................................................ 6

2.2.1 Latch Assembly Components.............................................................................. 7 2.2.2 Principal Drive Components................................................................................ 8

2.3 ELECTRONIC COMPONENTS....................................................................................... 9 2.3.1 Control Board ...................................................................................................... 9 2.3.2 Connector Pin Assignments .............................................................................. 10 2.3.3 Batteries ............................................................................................................ 10

SECTION 3 - NORMAL GATE OPERATION....................................................................... 11 3.1 MECHANICAL OPERATION........................................................................................ 12

3.1.1 Gate Opening .................................................................................................... 13 3.1.2 Gate Closing...................................................................................................... 13 3.1.3 Gate Opened While Closing.............................................................................. 13

3.2 CONTROL LOGIC (AUTOMATIC CLOSE MODE)........................................................... 14 3.2.1 PE Beam and Entry Mouth Safety Trigger ........................................................ 14 3.2.2 Opening and Closing Overloads ....................................................................... 15 3.2.3 Closing Timeout ................................................................................................ 15

SECTION 4 - DIAGNOSTIC DISPLAY................................................................................. 17 4.1 DIAGNOSTIC DISPLAY.............................................................................................. 18 4.2 DISPLAY OF CURRENT GATE STATE......................................................................... 19 4.3 DISPLAY OF ERRORS AND FAULTS ........................................................................... 20

4.3.1 Nomenclature .................................................................................................... 20 4.3.2 Fault and Error Indication Methodology ............................................................ 20 4.3.3 Fault Codes ....................................................................................................... 20 4.3.4 Clearing Fault Codes......................................................................................... 22

4.4 DISPLAY OF GATE CYCLES ...................................................................................... 23 4.5 CONFIGURABLE PARAMETERS ................................................................................. 23

4.5.1 General Method for Configuration Mode Selection ........................................... 23 4.5.2 Run Mode.......................................................................................................... 24 4.5.3 Gate Operation Mode Selection ........................................................................ 24 4.5.4 Gate Cycle Count .............................................................................................. 25 4.5.5 Gate Status Output Configuration ..................................................................... 25 4.5.6 Safety Re-try Time Configuration ...................................................................... 26 4.5.7 Gate Open Delay Configuration ........................................................................ 26 4.5.8 Power Source and Consumption Configuration ................................................ 26 4.5.9 Software Version Number Display .................................................................... 27 4.5.10 Long Safety Cut Response ........................................................................... 27

4.6 ROUTINE MAINTENANCE SCHEDULE......................................................................... 28 4.6.1 General Lubrication schedule............................................................................ 28 4.6.2 Component Replacement and Service Schedule.............................................. 28

SECTION 5 - BREAKDOWN TROUBLE SHOOTING ......................................................... 30 5.1 REPAIR CODE DESCRIPTIONS.................................................................................. 34

SECTION 6 - REPAIR/MAINTENANCE PROCEDURES..................................................... 38 6.1 GATE EMERGENCY OPENING PROCEDURE............................................................... 39 6.2 MASTER POST ACCESS DOOR REMOVAL/REPLACEMENT.......................................... 40 6.3 PULL-IN CABLE REPLACEMENT ................................................................................ 41

6.3.1 To remove a worn or broken Pull-in Cable... ..................................................... 41


iv

6.3.2 To install a new Pull-in Cable... ......................................................................... 42 6.4 ENTRY MOUTH ASSEMBLY REPLACEMENT................................................................. 44 6.5 MAIN OPERATING MODULE (MOM) REMOVAL/REPLACEMENT.................................... 46 6.6 MOTOR DRIVE ASSEMBLY REPLACEMENT ................................................................. 48 6.7 LATCH HOUSING ASSEMBLY REPLACEMENT .............................................................. 49 6.8 MAIN CABLE ASSEMBLY REPLACEMENT .................................................................... 50 6.9 COUNTERWEIGHT BAR ASSEMBLY REPLACEMENT ..................................................... 52 6.10 ELECTRICAL REPAIRS.............................................................................................. 53

6.10.1 Clearing Fault Indications.............................................................................. 53 6.10.2 Electronic control module replacement ......................................................... 53 6.10.3 Main Operating Module (MOM) wiring harness assembly replacement........ 55 6.10.4 Battery Replacement ..................................................................................... 56 6.10.5 Main Control Board fuse Replacement.......................................................... 56 6.10.6 Lock Microswitch Replacement..................................................................... 57 6.10.7 Replacement of Photoelectric (PE) unit ........................................................ 58

APPENDIX A : CONTROL BOARD SCHEMATICS ............................................................ 60

APPENDIX B : AUSTRALIAN AVERAGE ANNUAL MEDIAN TEMPERATURE ............... 64

APPENDIX C : BATTERY INSTALLATION, COMMISSIONING AND MAINTENANCE GUIDE................................................................................................................................... 66

APPENDIX D : BATTERY PRODUCT SAFETY DATA SHEET .......................................... 70

APPENDIX E : ACCESSORIES AND SPARE PARTS........................................................ 76


v

INTRODUCTION

This maintenance manual is intended as a guide both for the scheduled maintenance and the breakdown repair of the Cable Gate.

The manual is primarily intended for use by trained distributors and service personnel. However, many of the operations contained within can be carried out by competent gate owners and operators. Troubleshooting guides have been included to assist gate owners and operators make quick repairs to the gate. In some instances, however, the procedures contained in this manual should be completed only by trained service personnel. Where this is the case this is indicated in the manual.

In this manual, the words WARNING and CAUTION are used to mean the following:

WARNING

This heading means that the information that follows is provided to protect personnel

from injury.

CAUTION

This heading means that the information that follows is provided to protect equipment

from damage.


vi


1

Section 1 - Tools and Equipment


2

1.1 Required Tools

The following standard tools are recommended for completing service work on the Cable Gate.

Item Description/Use Qty 2.5 to 6 mm ball end driver set

Removal of various screws on the main operating module and post assemblies

1 Set

Small flat bladed screw driver

Screw connectors for access control systems. Removing spring clips on socket joints.

1

Large flat bladed screw driver

Levering plastic cap off cable end. 1

No. 2 PosiDrive™ Screw Driver

Removing screws on lid of electronics enclosure, Removal of screws on electronic control board.

1

Needle nosed pliers Recovering end of pull-in cable from entry mouth. Removing spring clips on socket joints.

1

7, 8 & 10 mm ring/open ended spanners

Removing various nuts 1 each

Side cutters (in good condition)

Trimming end of pull-in cable. 1

Ball Peen Hammer Attaching ferrules to main cable 1 Cordless Drill & drill bits

Drilling holes in main cable sheathing 1 Set

Pop Rivet Gun Attaching rivets to sheathing or reflectors 1 Kit Heavy Cotton Gloves Protect hands from rough fibres on cables 1 Ø2mm stiff wire or Ø2.5mm long series drill bit

Cleaning old fibres from pull-in cable out of hole in cable end

1

In additional to the standard tools listed above, it is recommended that the following specialist tools be purchased specifically to complete servicing work on the Cable Gate product. All of these tools are available through Access Technologies (WA) Pty Ltd.

Item Description/Use Qty System Zero™ Security Screwdriver

Removal of entry mouth Removal of post caps Removal of beacon bracket

1 driver

System Zero™ Security Socket – 6 mm Hex Drive

Removal of entry mouth 1 driver bit

PE Beam Reflector (Part Number 90-80-01)

Aligning photoelectric beam accurately 2

Fuse extraction tool Removing fuses from the main control board 1


3

Section 2 - Cable Gate Diagrams


4

2.1 External Cable Gate Components

The principal components visible from outside the Cable Gate are indicated in Figure 2-1 and Figure 2-2 below.

Figure 2-1: External components of the Master Post

Post Cap

Access Cover

Entry Mouth

Spine Attach Screws

Safety Trigger

PE Window

Main Cable

Pull-in Cable

Cable End


5

Figure 2-2: External components of Passive Post

Counterweight Bar

Main Cable

Impact Pad for Counterweight

Bar

Bolt Cage Nuts

Grille to protect PE reflectors

Post Cap

Security Cover Plate (for

counterweight bar)


6

2.2 Main Operating Module

The main operating module is located within the master post assembly, and contains all of the functional components required to open and close the gate. The principal components located on the main operating module are indicated in Figure 2-3 below.

Figure 2-3: Principle components of the Main Operating Module (MOM)

Electronics Enclosure

Motor Main

Control Board

Latch Assembly

Spine Latch

Release Rod

Handle PE Unit

(photoelectric) Drive

Assembly

Drive Shaft Viewing Direction


7

2.2.1 Latch Assembly Components The latch assembly components on the main operating module are indicated in Figure 2-4 below.

Figure 2-4: Latch Assembly components of the Main Operating Module (MOM)

Latch Housing

Top Sheave Latch

Lock Microswitch

Photoelectric (PE) unit

PE Horizontal Adjust Screws

Latch Spring

PE Vertical Adjust Screws


8

2.2.2 Principal Drive Components

The main drive components are indicated in

Figure 2-5 below.

Figure 2-5: Main drive components of the Main Operating Module (MOM)

Clutch Rotor

Clutch Armature

Disc

Winch Drum

Brake Finger

Brake Block

Main Shaft

Clutch Coil

Sprag Bearing Latch

Release Disc

Socket Joint (at end of Latch Release

Rod)

Motor


9

2.3 Electronic Components

2.3.1 Control Board

The electrical and sensing components located within the master post are indicated in Figure 2-6 and Figure 2-7 below. More detail on the control board can be found in Appendix A.

Figure 2-6: Main components of the Control Board

WARNING

Do not connect mains power to the control board.

Diagnostic Display

Clear Faults/ Enter Button

Left & Right Fob Buttons

Controller Reset Button

(Not to be used to clear faults)

Rotary Switch

BOM & ESN Numbers

Header for Radio

Receiver

Status LED’s - UP - Down - Road Loop - PE beam - Fob - Lock Switch - External Supply - Heart Beat

12-way connector “X2” (n.b. Pin 1 on

RHS)

Connector for MOM harness

6-way connector “X3”(n.b. Pin 1 on

RHS)

Main Battery Fuse

External Power Supply wires (24VAC plug

pack)

Antenna Connector

Access Control Fuse

Solar Panel Fuse

Serial Comms. Connector

12 1 6 1


10

2.3.2 Connector Pin Assignments All signal inputs are active low (i.e. pull to ground).

Table 2-1: Connector 12 Way (X2) & 6 Way (X3) Green terminal blocks

2.3.3 Batteries

Figure 2-7: Battery Location & Wiring

Pin X2 In/Out Type Description Max Current

/Voltage 4c-cable

core colour

6c-cable core

colour 1 Input Power 24 AC+ 1 Amp/33V 2 Input Power 24 AC- 1 Amp/33V 3 Input Power Solar Positive 1.2 Amp/33V 4 Input Power Solar Negative 1.2 Amp/33V 5 Input Signal Up 20 mA/24V Red Red 6 Input Signal Down 20 mA/24V Green Green 7 Input Signal Exit Road loop 20 mA/24V 8 Output Power 12 V Access Control Power 500 mA 9 Output Power 12 V Access Control Ground 500 mA Black Black 10 Input Signal Remote Clear Faults 20 mA/24V Yellow Yellow 11 Input Signal Spare Input (Not used) 20 mA/24V 12 Output Power 12 V Access Control Ground 500 mA

PinX3 In/Out Type Description Max Current

/Voltage 4c-cable

core colour

6c-cable core

colour 1 Output Power 24 V DC 1 Amp 2 Output Power Ground 1 Amp 3 Output Power Gate Locked 0 500 mA/33V Blue 4 Output Power Gate Locked 1 500 mA/33V White 5 Input Signal Safety Loop 20 mA/24V 6 Output Power 12V Sensor Power 200 mA

Negative Wire

(black)

Positive wire (red)


11

Section 3 - Normal Gate Operation


12

This section describes in detail the normal operation of the Cable Gate, to assist in understanding the maintenance requirements.

3.1 Mechanical Operation

This sub-section deals only with the mechanical behaviour of the Cable Gate. A discussion of the control system logic can be found in section 3.2 below.

The cable gate uses a DC electric motor to both release the main cable and to winch in the pull-in cable. The function performed by the motor is determined by the direction of rotation selected. Motor movement in both of these directions is further described below.

Figure 3-1: Rear View of Master Post with door removed

Motor

Electronics Enclosure

Batteries

Drive Assembly

Post Cap

Latch & Housing

Spine Bracket

Master Post

Side Access Cover

Motor Connector


13

3.1.1 Gate Opening

When the gate controller receives an “open” command, the motor is driven in the “open” direction. If the MOM is viewed in the orientation shown in Figure 2-3, the shaft will rotate anti-clockwise.

In this instance the latch release arm rotates with the motor under the action of the sprag clutch assembly. The sprag clutch is also known as a “one way bearing” since it permits free rotation in one direction (closing), while “locking up” in the other direction (opening) to provide movement to the latch release rod. The latch release rod opens the latch, which in turn releases the main cable.

The “lock” microswitch is activated from a cam located on the latch, and is used to control the duration of motor drive during opening.

When the gate is in the opening mode, the electromagnetic clutch is not energised, therefore permitting the main cable to fall freely to the ground when the latch is released.

When the main cable falls to the ground, the counterweight and counterweight bar system in the passive post causes the main cable to be retracted neatly against the passive post. The main cable remains fixed to the passive post at all times.

In the master post the brake block stops the winch drum from over-spooling, eliminating the risk of entanglement of the pull-in cable.

3.1.2 Gate Closing

The gate controller drives the motor in the “close” direction. In this instance the main drive shaft will rotate clockwise when viewed as shown in Figure 2-3.

In this instance the latch release arm, and therefore the latch also, will close under spring pressure and then remain stationary since the sprag clutch is operating in the freewheeling direction.

The electromagnetic clutch is energised and the motor rotation is transferred to the winch drum that rotates slowly to retract the main cable assembly.

As the winch drum retracts the pull-in cable, the brake finger is used to ensure that the correct cable lay is achieved onto the winch drum.

When the “cable end” component enters the entry mouth, it causes the latch to be depressed. As the cable end reaches the end of its travel the latch springs back into place behind the cable end, causing the cable end to be locked firmly in place.

When the latch returns to the locked position the “lock” microswitch is de-activated, which signals to the electronic control unit that power to the clutch should cease. Shortly after the clutch has been de-energised the motor is stopped. The delay between the clutch being de-energised and the motor turning off is designed to ensure that the latch has sufficient time to move into the completely locked position; the latch cannot move upwards unless the motor is turning in the “close” direction, due to the action of the sprag clutch.

A short time after the main cable is locked in position, the electronic control unit enters “sleep” mode to conserve battery power, until the next gate activation signal is received.

3.1.3 Gate Opened While Closing

It may occur that the gate is required to re-open while the closing cycle is incomplete. In this instance, the gate behaves as if it were opening from a locked position. The motor reverses direction (depressing the latch), and the electromagnetic clutch is released to permit freefall of the main cable.


14

3.2 Control Logic (Automatic Close Mode)

The gate can receive a “down” signal from a radio remote key fob, proximity card system, keypad system, vehicle detection loop, or any other proprietary access control system. The control system registers a “down” signal when the “down” pin on the main control board connector is grounded. Upon receiving a “down” signal the following control events occur:

− The motor is driven in the “open” direction until the “lock” microswitch is opened. A pre-defined period after the switch contact is broken the motor stops running.

− A counter is started when the “down” signal is received. If the pre-defined counter period elapses, without any further control system input, the gate controller will close the gate in the normal manner (as described in section 3.1.2 above).

− Breaking the PE beam while the timer is activated changes the behaviour of the gate. Breaking the PE beam causes the gate to enter the “closing” mode, as it is assumed that the vehicle activating the gate has driven through the gate. Section 3.2.1 below explains the action of breaking the PE beam in more detail.

− If the gate receives another “Down” signal prior to expiry of the timer, the timer is reset to zero, and the timing process commences again. In this instance, the gate is said to enter “pending” mode, and breaking the PE beam does not have the normal effect. If the PE beam is broken after the second “down” signal is received, the gate does not close as it is assumed that a second vehicle is waiting to enter the gate. Only after the PE beam is broken a second time will the gate begin to close. Only one “pending” signal is stored by the controller per gate opening, i.e. a maximum of two vehicles can pass before the gate will begin to close.

3.2.1 PE Beam and Entry Mouth Safety Trigger

As mentioned above, breaking the PE beam while the gate is in the “open” state changes the behaviour of the gate:

If the gate was closing when the PE beam is broken, the gate will immediately re-open.

If the gate is open when the PE beam is broken, the gate will begin to close once the PE beam has been re-established. The gate will not attempt to close while the PE beam remains continuously broken.

If the PE beam is broken while the gate is in the “open” state, there exists a short delay between the beam being re-established and the commencement of gate closure. This period is called the safety period, and is included to ensure that adequate time is allowed in the event that the car is towing a trailer (multiple beam breaks).

If the PE beam is broken while the gate is in the Closing state, the controller will re-open the gate. The gate will begin to re-close immediately once the beam has been re-established.

It should be noted that depression of the “safety trigger” located on the entry mouth is functionally equivalent to breaking the PE beam. In fact, the safety trigger is mechanically connected to a “shutter” located above the PE beam that causes a break in the beam identical to that achieved by a car breaking the beam.


15

3.2.2 Opening and Closing Overloads

The motor on the gate is protected against excessive current draw in either the “opening” or “closing” modes. This current overload may be caused by such events as the main cable becoming lodged under a vehicle in the “closing” state, or a person sitting on the main cable when the controller receives an “open” signal.

If the gate is closing while the motor current limit is exceeded, the controller will open the gate, wait two seconds, and then begin to try closing the gate once more.

If the gate is attempting to open and the current limit is exceeded, the controller will stop the motor, wait two seconds, and then begin to retry opening the gate again.

The gate controller will try for a maximum of five times to overcome the overload condition in either the opening or closing mode. If five overloads of the same type are received in one gate opening cycle the gate will enter “lock-out” mode, and will not respond to any more inputs until the “clear faults” button on the main control board is pressed. This action is taken to prevent mechanical damage from occurring to the gate in the event that the overloads are caused by a rigid obstruction.

3.2.3 Closing Timeout

A timer is started once the gate enters the “closing” mode. Typically, this timer will reach around eight seconds before the cable end latches in the home position, finishing the gate close cycle.

If the timer reaches a pre-determined value (typically 11 seconds) during the pull-in cycle the controller assumes that the pull-in cable is broken. This action is taken to prevent mechanical damage from occurring to the motor drive assembly due to the broken pull-in cable. In this instance the gate will retry closing 5 times, before it enters “lock out” mode. After replacing the pull-in cable the gate can be recovered from “lock out” mode by pressing the “clear faults” button on the main control board (refer Figure 2-6).


16


17

Section 4 - Diagnostic Display


18

4.1 Diagnostic Display

The Cable Gate is fitted with two seven-segment LED displays, which are used for a variety of purposes including diagnostic display of gate faults. The LED display is viewable through the Perspex window in the rear door of the master post, as shown in Figure 4-1.

Figure 4-1: Rear of Master Post showing viewing window for diagnostic display

There is also a group of seven discrete LED’s viewable to the left of the seven-segment LED display, which primarily indicates sensor status and gate state, and is used for diagnostic purposes in conjunction with the seven-segment LED displays.

Viewing Window for Diagnostic

Display


19

4.2 Display of Current Gate State

When the cable gate is operating normally, the diagnostic display will show the current state of the gate, unless the display has been blanked. Refer to Figure 4-1 above for the location of the diagnostic display. When the current state is being displayed the left and right digits on the diagnostic display have different purposes.

The left digit of the diagnostic displays a letter, and possibly a decimal point, to indicate whether the gate is closed, closing, open or opening according to the following table.

Table 4-1: Left digit gate state display

Left digit of diagnostic display Gate state C Closed C. Closing o Open o. Opening

The right digit of the diagnostic display shows a number giving the reason why the gate is in its current state. The meaning of the numbers is shown in the following table.

Table 4-2: Right digit gate state display

Right digit of diagnostic display

Reason gate is in current state

1 Up signal 2 Down signal 3 Not Used 4 PE beam 5 Key Fob

When the gate has been idle for 60 seconds the diagnostic display will go blank.


20

4.3 Display of Errors and Faults

4.3.1 Nomenclature

Errors – Do not cause the gate to shut down, but require monitoring to ensure that more serious problems do not develop.

Faults – Are serious enough to require shutdown of the gate, and must be attended to before gate operation can re-commence. Gate operation is re-commenced through pressing the “Clear faults” button on the main control board.

4.3.2 Fault and Error Indication Methodology

Both errors and faults are displayed using a number in the range of 10 to 99 on the 7-segment LED displays. The errors and faults are both displayed in real time (i.e. as they occur). Errors are displayed for a period of 20 seconds, before the display returns to the default setting. Conversely, faults are displayed permanently until the “clear faults” button is depressed.

4.3.3 Fault Codes

The fault and error codes are divided into groups according to component or sub-assembly that they are likely to be caused by. The specific groupings and error/fault codes are as follows:

Table 4-3: Fault and Error codes (multiple pages)

10 – 19: Errors associated with the

latch assembly.

10 – “Latching overload” error – Occurs after the lock switch has been depressed upon closing. This may indicate an obstruction in the latch housing, or extreme wear of the “cable end” component.

11 – “No lock switch transition during opening” error. This may indicate a broken latch release arm, or the sprag clutch slipping on the shaft. This error occurs early in the opening cycle, unlike error 14 that occurs early in the closing cycle.

12 – “No lock switch transition for latch closed” error. This means that the latch has not returned to the home position after the cable end has arrived home. This may indicate a failed latch spring, or may indicate that the latch itself is jammed.

13 – “Opening overload” error. This may be caused by severe wear of the cable end component, or may indicate a heavy weight has been placed on the main cable during opening.

14 – “No lock switch transition after start of close” error. This means that the latch does not return to the home position within a short time after the start of the closing event. This may indicate a broken latch spring, or a jammed latch.

15 – “Lock switch depressed after de clutch” error. This means that the latch has reopened after the clutch has turned off on closing. This can be caused by burrs on the cable end causing the latch to bounce down upon closing.


21


20 – 29: Errors associated with the

motor drive assembly or cable errors

(excluding electro-magnetic clutch

errors)

20 – “Closing overload” (Occurs before the lock switch has been depressed). This may occur due to either something preventing the cable from entering the entry mouth, the presence of a heavy weight on the main cable during closing, or by a pull-in cable becoming disconnected from the end of the main cable.

21 - “No lock switch transition (timeout) during close” error. This is likely to be either a broken pull-in cable, or a slipping electro-magnetic clutch.

22 – “Motor current too high” error. This typically indicates failure of the motor windings.

23 – “Motor current too low” error. Either motor wiring faults or the motor connector not being made may cause this.

24 – “Motor start current too high” error. This is usually a short circuit in the motor.

25 – “Motor short circuit” error. This may indicate a direct short of either motor windings or the wiring harness.

26 – “Latch has moved up following opening” error. This may indicate that the sprag clutch has failed, or the drive shaft is not properly connected to the motor shaft.

27 – “Closing time too short” error. This typically indicates that the cable end component is not dropping out far enough upon cable release. This may be due to a frayed pull-in cable, jammed top sheave or too heavy brake spring.

30 – 39: Electromagnetic

clutch errors:

No electromagnetic clutch error numbers are implemented at this time.

40- 49: Software errors:

40 – “Timer manager not initialised” error.

41 – “Timer manager invalid pointer” error.

42 – “Timer manager invalid size” error.

43 – “Closing end logic” error

44 – “Bad initialisation” error.

These errors are very unlikely to occur – consult Access Technologies (WA) for advice on how to rectify these errors.

50 – 59: Electronic hardware errors:

No Electronic hardware errors are implemented at this time.


22


60 – 69: PE (photoelectric) beam

errors:

60 – “Safety Beam Cut on Open” error. This error occurs when the safety beam is cut within the first 500 milliseconds of the gate being open. The basis for this error is that it is unlikely that the PE beam can be cut by a vehicle within 500 milliseconds of the gate opening. This error will not cause the gate to go into “lock out” mode. The error is usually due to misalignment of the PE beam, a foreign object blocking the path of the beam, or condensation forming on the reflectors or PE window.

61 – “Safety Beam Cut for too Long” error. This error occurs when the beam has been continually cut for more than 60 seconds. This error will not cause the gate to go into “lock out” mode. Depending on the configuration of the long safety cut response mode (refer section 4.5.10 below) the gate will either remain open or begin to close after this error is detected. The error is usually due to misalignment of the PE beam, a foreign object blocking the path of the beam, or condensation forming on the reflectors or PE window.

61 – “Safety Beam Pulse on Open” error. This error occurs when the PE beam is briefly cut and re-established within the first 500 milliseconds of the gate being open. This error will not cause the gate to go into “lock out” mode. The gate will ignore this brief safety cut, as it is most likely due to the beam being badly aligned and vibration of the post causing it to break as the gate opens.

70-79: Battery and charging system

errors.

70 – “Low battery voltage” error. The following may cause this:

− Gate usage in excess of the sustainable rate. Refer to the Cable Gate Sales and Marketing Manual for further information on the maximum allowable daily cycle rates,

− Inadequate solar panel current (where fitted).

− Failed battery

80-89: “Gate activation” errors.

No gate activation error numbers are implemented at this time.

90-99: Beacon errors: No beacon error numbers are implemented at this time.

4.3.4 Clearing Fault Codes

Once a system fault has been repaired, the Clear Faults button (CF/Enter) should be pressed to return the gate to its normal operating state.

Note! If the system fault has left the gate in the down position then one of the fob buttons must be pressed to return the gate to the closed position so that normal operation can resume. It will do this after the PE beam times out.


23

4.4 Display of Gate Cycles

The accumulated gate cycles can be displayed at any time on the seven-segment LED display panel.

“Gate cycle display” mode is entered through setting the rotary switch on the Main Control Board to position 2.

When this switch position is selected, the 2-digit, 7-segment display will show the letters “CC” to indicate that the “Cycle Count” mode has been selected.

The gate cycle count display is commenced through pressing the CF/Enter button.

If the cycle count was 123 579 cycles, it would be displayed as shown in Figure 4-2.

1 2 1 second Break

3. 5 1 second Break

7 9.

Figure 4-2: Example of cycle count display

The cycle count display sequence can be repeated by repressing the "CF/Enter" button.

Turn the rotary switch back to position 0 to return to normal gate operation.

4.5 Configurable Parameters

The following configuration parameters are entered through the 16 position rotary switch located on the main control board:

(Refer to Figure 2-6 for the location of the rotary switch and associated buttons)

4.5.1 General Method for Configuration Mode Selection

The 16-position rotary switch is used to select both the gate operating mode and for entering various calibration modes.

When the rotary switch is set to a certain position, two “alpha” characters are displayed to indicate the mode selection that has been made. For example, the 2-digit, 7-segment display may show the letters “CC” to indicate that the “cycle counter” reset mode has been selected (switch position 2).

These letters will be displayed until the Clear Faults/ Enter button (Marked CF/Enter) is pressed. Pressing the Clear faults/enter button (Marked CF) brings up the default value of the user-defined parameter associated with the particular operating mode selected.

The parameters are modified by using the left key fob button (Marked F1) and the right key fob button (Marked F2). The left fob button (F1) upwardly increments the parameter value, while the right fob button (F2) downwardly increments the parameter value. The numbers on the display will be flashing at this point to indicate that the display value differs from the parameter value saved in memory.

Once the correct value has been obtained, it is stored in memory through pressing the CF/Enter button. When this button is pressed the display will stop flashing to indicate that the selected parameter has been permanently stored in memory.

At this point the 16-position rotary switch can be set back to the operating mode position (switch position 0).


24

4.5.2 Run Mode

Position 0 – This position is used to run the gate in whatever mode is selected using position 1. Gate operation in the selected mode commences immediately upon selecting position 0 (following a brief “debounce” period). After entering this switch position the 2-digit, 7-segment LED display panel momentarily shows the characters “8.8.” before reverting to displaying the current gate state described in section 4.2 above (i.e. closing, opening etc).

4.5.3 Gate Operation Mode Selection

Position 1 – This switch position is used to select the gate-operating mode to be run in position 0.

Upon entering this switch position the diagnostic display will show the letters “oP” to indicate the operation mode selection position has been reached.

The following modes are available and can be selected using the procedure detailed in section 4.5.1 above: Mode 0 = Disabled Mode

This is the mode that the gate enters when gate parameters are being modified. In this mode the key fob input is disabled (although F1 and F2 are enabled) to prevent a key fob user from inadvertently changing control parameters from a location adjacent to the gate. This mode setting is of no value to the gate operator and is only every used during shipping or when the gate is left idle for long periods of time.

Mode 1= Up mode.

In this mode the gate will remain locked up regardless on any gate activation signals received. For this reason caution should be exercised in using this mode. The gate must already be closed for it to remain up. If the gate is open it will remain open.

While the gate is in up mode the diagnostic display will flash “UP” and the red beacon (if fitted) will flash and the red traffic light will illuminate (if fitted).

Mode 2 = Down mode.

When this mode is selected the cable will drop, and will remain down until a new mode is selected. While in this mode the green beacon and green traffic light (if fitted) will illuminate and the diagnostic display will flash “dn”.

In this mode the processor goes to sleep to conserve battery power.

When selecting auto mode after being in the down mode, one of the fob buttons must be pressed to return the gate to the closed state. It will do this after the PE beam times out.

Mode 3= Automatic mode.

This is the default-operating mode of the gate as supplied. The gate will respond to all gate activation signals in this mode, as described in section 3.2 above.

Mode 4= Toggle mode.

In this mode the key fob can be used to toggle the state of the gate. ( i.e. depressing the key fob will release the gate, and depressing it again will cause the cable to retract home.)


25

Mode 5 = Test Cycle mode.

When in this mode the gate will automatically cycle up and down at a fast rate.

If a gate activation signal or safety signal (PE beam break) is received the gate responds respond in the usual manner.

4.5.4 Gate Cycle Count

Position 2 – This switch position is used to show the total number of cycles the gate has completed.

Its use is described in section 4.4 above.

4.5.5 Gate Status Output Configuration

Position 3 – This switch position is used to configure the behaviour of the two gates status output connections.

Upon selecting this switch position the display will show the letters “ou” (lower case) to confirm that the “output select” mode has been entered.

The control system is designed with .two outputs for indicating the gate status to remote devices, such as fire alarm mimic panels, security alarms, or programmable logic control systems (PLC’s).

The output lines are called “gate locked output 0” and “gate locked output 1”. The pins for these outputs are found on the Main Control Board (refer to Section 2.3.2 above for details).

The following modes are available and can be selected using the procedure detailed in section 4.5.1 above:

Table 4-4: Gate locked output modes

Mode Description Gate Locked 0 Gate Locked 1 0 Always off FLOATING FLOATING 1 Fault / Open GROUNDED in Fault GROUNDED if Open 2 Inverse of mode 1 FLOATING in Fault FLOATING if Open 3 Default Fault / Locked GROUNDED in Fault GROUNDED if Locked 4 Inverse of mode 3 FLOATING in Fault FLOATING if Locked 5 Open / Locked GROUNDED if Open GROUNDED if Locked 6 Inverse of mode 5 FLOATING if Open FLOATING if Locked

CAUTION

When the gate is in the fault state, it is not possible to determine with certainty whether the gate is locked or not. Therefore, care should be taken in using the

open/locked outputs when the gate is in the fault state.


26

4.5.6 Safety Re-try Time Configuration

Position 4 – This configuration parameter can be used by the service technician to set the period between when a safety signal is re-established and when the gate attempts to close, when in the “open” state.

When this switch position is selected the display shows the letters “PE” to indicate that the “photoelectric (PE) Beam Safety Time” is being set.

The range of permissible settings is 0 seconds to 65 seconds. Scrolling beyond 65 seconds forces the display back to 0 seconds. The default setting is 2 seconds.

4.5.7 Gate Open Delay Configuration

Position 5 – This position sets the period that the gate remains open for, without the influence of a safety signal or other gate activation signal i.e. the gate open delay period.

When this switch position is selected the display shows the letters “od” (lower case) to indicate that the “open delay” period is being set.

The range of settings is 0 seconds to 65 seconds. Scrolling beyond 65 seconds forces the display back to 0 seconds.

It is possible to configure the safety time for different operating modes; depending on which operating mode the open delay period configuration was entered from. The default values for the open delay time are as follows:

• Automatic Mode = 25 Seconds (by default). This value if often set higher if gate users have to make their way back into a car after the gate has been opened.

• Toggle Mode = 1 second (by default)

• Test Cycle Mode = 1 second (by default)

4.5.8 Power Source and Consumption Configuration

Position 6 – This switch position configures the gate to run from different power sources (and have variable power consumption) as indicated in the table below:

When this switch position is selected the display panel shows the characters “PC” to indicate that the “Power Configuration” mode has been selected.


Table 4-5: Power Source Configuration Modes Power Mode

Indicator Power Source

0 No standard power source used

1 AC Plug Pack Used 2 Solar Panel Used

Power Mode 0 should be selected wherever the gate is operated from neither an AC plug pack nor a solar panel assembly, both of which can be supplied by Access Technologies (WA) Technologies. For example, some customers may prefer to run the gate from a 24-volt wet cell, lead-acid battery, with charging not provided by the Cable Gate control system. If Power Mode 0 is selected, the gate controller will not display an error if the anticipated charging current is not observed for an extended period.


27

4.5.9 Software Version Number Display

Position 7 – This switch position is used by the Service Technician to record the gate operating Software Version Number.

When this mode is selected the display shows the letters “SF” to indicate that the “SoFtware Version Number” is being selected.

This information is displayed (when the clear faults/enter button is pressed) in the format “x.y” to indicate both the version and sub-version numbers.

This switch position is only used to view the Software Version Number – no editing of the version number is available.

4.5.10 Long Safety Cut Response

Position 8 – This switch position is used to configure how the gate responds when the safety beam is cut for a long period of time.

When this mode is selected the display shows the letters “SC” to indicate that the “Safety Cut” mode is being selected.


Table 4-6: Long Safety Cut Response Modes Long Safety

Cut Response Number

Response

0 The gate will remain open as long as the safety beam is cut

1 If the safety beam is cut for more than 1 minute, the gate will automatically close (even thought the safety beam remains cut).

2 (Factory default)

If the safety beam was cut on open and remains cut for 1 minute, the gate will automatically close (even though the safety beam remains cut).

Long safety beam cuts can be caused by situations such as: • A car legitimately parked across gate. • A user blocking the beam to allow non-authorised vehicles to enter. • Condensation forming on the beam’s lens on cold wet mornings.

Thus the “Safety Cut” mode selection is designed to allow the user to decide how they want the gate to behave in these situations.


28

4.6 Routine Maintenance Schedule

4.6.1 General Lubrication schedule

Every two weeks the back end of the Cable End component should be sprayed with WD40® (or equivalent product) in the location indicated in Figure 4-3 below.

Figure 4-3: Correct method of applying lubrication to cable end

4.6.2 Component Replacement and Service Schedule

− Inspect pull-in cable, and “cable end wear ring” at 20,000 cycles or 12-months of operation. Note that if the road surface is not too abrasive the life of the wear ring may be extended – replace only if necessary. Conversely, the pull-in cable should always be replaced every 20,000 cycles (or 12-months).

− Inspect Main Cable sheathing at approx. 60,000 cycles or three years of operation. Replace only if there is evidence of tearing or excessive wear along the lower edge.

− Inspect Main Cable at 200,000 cycles. Replace only if there is evidence of broken cable fibres or permanent bend in the cable.

− Inspect Pull-in Cable Sheave (Pulley), Latch, Cable End, Passive Post Wear Strip, and Entry Mouth at 400,000 cycles. Replace components as necessary.

Replace the batteries at the interval specified in Table 4-7. Refer to Appendix B to determine the mean temperature in the region. Note that the mean temperature does not exceed 30ºC in Australia. Also note that Table 4-7 only applies to Cable Gates being charged by an AC Plug Pack. The life of batteries in solar charging situations is much shorter and cannot be reliably estimated. Batteries used in solar application should be replaced at half the interval specified in Table 4-7 if reliable gate operation is to be assured.

Lubricant sprayed onto

this region


29

Table 4-7: Battery replacement schedule (depending on temperature) for Cable Gates being charged

by an AC plug pack Mean temperature:

50th percentile Battery replacement

interval

<18ºC 5 years

18-21ºC 4 years

21-27ºC 3 years

27-33ºC 2 years

33ºC+ 1 year


30

Section 5 - Breakdown Trouble Shooting


31

There are a number of reasons why the Cable Gate may fail to open or fail to close correctly.

If the gate will not open, then refer to Table 5-1 to help diagnose the fault and section 5.1 below for an explanation of how to correct the fault.

If the gate will not close, then refer to Table 5-2 to help diagnose the fault and section 5.1 below for an explanation of how to correct the fault.


32

Table 5-1: “Gate will not open” Fault Table

Error Site L.E.D. Indicator Lamps1 2

7 Segment Fault Code3 or Description

Solar or p/pack4

UP DN XL PE FO LK ES5

HB6

Cause of Fault Mechanism Repair Code

Blank x L _ _ _ _ _ L F UP signal active Disable UP signal from activation device7 A Blank x _ _ _ _ _ _ L F No DN signal Activation device faulty - not generating DN signal C Blank x _ _ _ _ _ _ L F Clutch not releasing Clutched jammed or held on S Blank P _ _ _ _ _ _ _ _ Flat batteries Plug pack switched off or unplugged D Blank S _ _ _ _ _ _ _ _ Flat batteries Solar power insufficient or disconnected E UP x _ _ _ _ _ _ L F User program Gate is programmed to stay in UP position F 10, 11, 12, 14, 15, 26, 27

x _ _ _ _ _ _ L F Latch Mechanism When 11 or 14, possible battery disconnected else Technician to visit site

G, T

13 x _ _ _ _ _ _ L F Opening overload Person(s) sitting on cable in UP position, latch wear H, T 22, 24, 25 x _ _ _ _ _ _ L F Motor over-current Motor shorted out - excessive current detected K 23 x _ _ _ _ _ _ L F Motor under-current Motor open circuit or not connected L 40,44 x _ _ _ _ _ _ L F Software Error See repair code explanation O 70 P _ _ _ _ _ _ _ F Batteries need

recharging Plug pack switched off or unplugged D

70 S _ _ _ _ _ _ _ F Batteries need recharging

Solar power insufficient or disconnected E

1 To view the indicator lamps on a solar site, press the Key Fob or the F1 button. 2 Options (L for lamp on, “_“ for lamp off, F for lamp flashing) 3 Read through a hole in the gate’s lockable door: Options (blank, a two digit numeric code or two digit symbolic code). In both solar and plug pack powered gates, the 7-segment displays are blanked 60 seconds after the last gate cycle. 4 Installation options (S for solar, P for plug pack or “x“ for don’t care) 5 The ES and HB LED’s are never turned off to save power in both solar and plug pack-powered gates. 6 The HB LED flashes on/off at 50/50 in a plug pack gate and 10/100 in a solar gate. 7 Activation devices, such as key fob, Office Box, Road Loop, Prox Card Reader, Intercom.


33

Table 5-2: “Gate will not close” Fault Table Error Site L.E.D. Indicator Lamps8

7 Segment Fault Code or Description

Solar or p/pack

UP DN X L PE FO LK ES9

HB10

Cause of Fault Mechanism Repair Code

Blank x _ L _ _ _ _ L F DN signal active Disable DN signal from activation device B Blank x _ _ L _ _ _ L F Exit Road Loop Exit Road Loop faulty, active or too sensitive P Blank x _ _ _ L _ _ L F PE (safety) beam Safety beam faulty or object detected Q Blank x _ _ _ _ L _ L F Key Fob or receiver Key Fob or receiver faulty R Blank x _ _ _ _ _ _ L F Controller lost state After fault is cleared, gate needs to be resynchronised V Blank P _ _ _ _ _ _ _ _ Flat batteries Plug pack switched off or unplugged D Blank S _ _ _ _ _ _ _ _ Flat batteries Solar power insufficient or disconnected E

dn x _ _ _ _ _ _ L F User program Gate is programmed to stay in DN position F 10, 11, 12, 14, 15, 26, 27

x _ _ _ _ _ _ L F Latch Mechanism When 11 or 14 possible battery disconnected else Technician to visit site

G

20 x _ _ _ _ _ _ L F Closing overload Person(s) standing on cable in DN position I, U 21 x _ _ _ _ _ _ L F Broken pull-in cable Replace the broken pull-in cable J

22, 24, 25 x _ _ _ _ _ _ L F Motor over-current Motor shorted out - excessive current detected K 23 x _ _ _ _ _ _ L F Motor under-current Motor open circuit or not connected L

60,61 x _ _ _ _ _ _ L F PE (safety) beam failure PE (safety) beam faulty, out of alignment, obstructed or condensation

M, N

62 x _ _ _ _ _ _ L F PE (safety) beam failure PE (safety) beam intermittent operation N 40,44 x _ _ _ _ _ _ L F Software Error See repair code explanation O

70 P _ _ _ _ _ _ _ F Batteries need recharging Plug pack switched off or unplugged D 70 S _ _ _ _ _ _ _ F Batteries need recharging Solar power insufficient or disconnected E Pull-in cable broken By Inspection Main cable broken By Inspection Post damaged by impact By Inspection

8 To view the indicator lamps on a solar site, press the Key Fob or the F1 button 9 The ES and HB LED’s are never turned off to save power in both solar and plug pack-powered gates. 10 The HB LED flashes on/off at 50/50 in a plug pack gate and 10/100 in a solar gate.


34

5.1 Repair Code Descriptions

Repair Code

Description Tests - Actions

A An activation device or installed switch may have the “UP” position selected.

Check switch, or connector X2 pin 5 being pulled low.

B An activation device, such as an Office Box, may have the “DN” position selected.

Check Office Box switch, or connector X2 pin 6 being pulled low.

C Activation Device

− Key Fob Transmitter: battery may be flat. Check for red light on Key Fob to test battery.

− Key Fob Receiver: receiver may be faulty. Check for red light on receiver card when Key Fob is pressed

− Key Fob Receiver: Key Fob may not be programmed into receiver.

Program Key Fob into receiver

D Plug pack switched off or unplugged. − Check plug pack is plugged in. − Check plug pack is switched on.

− Check light on plug pack enclosure is lit. If not, replace plug pack

− Check ES LED on controller is now lit. If not, check wiring and 12way green connector is plugged in.

Allow batteries to recharge for 30 minutes before using gate.

E Solar power insufficient or disconnected

− Check solar panel fuse not blown ES led lit will prove fuse ok

− Check solar panel not obstructed or covered

− Excessive number of cycles beyond initial design values

Get cycle count and re-calculate the number of panels required.

− Activation device added and additional current not taken into account.

Check recent installs for this site.

− Activation device, i.e. road loop, remaining on permanently

F Gate can be programmed to remain in the UP or DN position

Overrides all activation signals

G When error 11 or 14 shows on opening, it could be due to a disconnected battery or faulty battery cables. As the motor would be running slowly being driven from the plug pack alone the latch processes would time out hence the generation of error 11 and 14.

Check that the batteries are connected securely. If the terminals are loose, use a pair of pliers to close the contacts slightly.

H Person(s) sitting on cable in the UP position


35

Repair Code


I Person(s) standing on cable in the DN position

J Replace broken pull-in cable Use procedure detailed in section 6.3 below.

K Motor shorted out – excessive current detected − Check if the rotor is jammed. − Check if the armature is shorted out. − Check if motor cables are shorted out

L Motor open circuit or not connected − Check if the motor is internally open circuited − Check if the motor is connected − Check if motor cables are broken

M PE (safety) beam faulty, out of alignment, or obstructed

− Check if moisture has formed on the reflector or PE beam window.

If so, remove moisture from surfaces.

− Check if APWR fuse is intact. Replace fuse if broken.

N PE (safety) beam intermittent operation

− Check PE beam alignment. See procedure in section 6.10.7.1 below

O Software Error detected – possible causes are: - − Timer manager not initialised − Timer manager invalid pointer − Timer manager invalid size − Closing end logic error − Bad initialisation

Report error manufacturer.

P Exit Road Loop faulty, active or too sensitive (Don’t wire to DN pin)

− Check for broken road loop. Replace

− Check for sensitivity set too high (false triggers on rain water).

Set a lower sensitivity level

− Check for permanent presence set on loop controller

Q Safety beam faulty or object detected − Check for object permanently blocking beam. − Check for object blocked in cable entry

mouth.

Gate can be programmed to ignore safety beam after a fixed timeout.

− Check PE window and reflectors are clean

− Check alignment of PE beam Use procedure outlined in section 6.10.7.1 below.

− Check sensitivity of safety beam Take top off PE beam unit and check sensitivity is set to maximum


36

Repair Code


R Key Fob or receiver faulty − Check for short circuit at output of receiver. − Check for Key Fob transmitter continuously

transmitting.

S Clutch not disengaging Attempt to turn winch drum by hand – replace drive assembly.

T Latch mechanism failure. Is extreme wear visible on the latch or cable end? – Replace latch or cable end

U Main Cable Set to High Measure height from roadway to centreline of main cable is within limits stated in section 6.8 below.

V Gate lost state after fault is cleared Press F1 button on control board; or key fob.

AA2 If the description of a particular fault does not match any in the diagnosis chart and the gate refuses to open, get the operator to remove the 12 way green connector from the controller board and press the F1 button. If the controller board is operating correctly, and there are no mechanical errors, the gate should open. Faultfinding can then be focused on the wiring of the 12-way connector.

AA3 When beginning the conversation with the customer, ask the following: − Plug pack or solar site? − What activation devices are used? (i.e. Key Fob, Exit Road Loop, Entry Road Loop,

Office Box, Swipe Card, Keypad, Intercom, Other) − Has a technician recently visited the site? − Is the battery connected? − Has the plug pack (if fitted) been accidentally turned off?


37


38

Section 6 - Repair/Maintenance Procedures


39

6.1 Gate Emergency Opening Procedure

In the event that the Cable Gate is unable to be opened using normal means, and is blocking traffic flow, the following procedure may be used to open the gate.

WARNING

The pull-in cable may have very small broken fibers that will cut skin if handled. Do not handle the pull-in cable with bare hands. Stand well clear of the pull-in cable during release (while the rear door is removed) as the cable

may flick unpredictably outside the master post.

1. Remove the back door from the master post (see section 6.2 below).

2. Disconnect the motor connector.

3. The pull-in cable is the small vertical cable, which goes from a small pulley near the top of the post to a winch drum near the bottom of the post. Check that the pull-in cable is not jammed on anything and that the winch drum is free to move.

a. If the winch drum is not free to move and cannot be freed, then it will be necessary to cut the pull-in cable with a pair of wire cutters. In this instance the drive assembly will require repair or replacement.

b. If the pull-in cable is jammed on anything it will be necessary to free the jam or cut the pull-in cable with a pair of wire cutters.

4. Push down on the manual latch release lever to unlock the cable end and allow the main cable to fall to the ground. Once the latch is released the pull-in cable will move rapidly. Keep body parts well clear of the pull-in cable as this is done, as it may flick around as the latch is released.

5. Reattach back door to master post.

Figure 6-1: Manual Latch Release for Emergency Gate Opening

Manual Latch Release Lever


40

6.2 Master Post Access Door Removal/Replacement

The door in the back of the master post will frequently need to be removed to gain access to the main operating module (MOM). The procedure for removing the door is as follows:

1. Insert the key and turn 90º clockwise.

2. Lift the door upwards vertically for ~10mm before pulling the top of the door outwards and continuing to lift upwards. The bottom of the door will clear the lip at the base of the post and fall out.

CAUTION

Do not use the key as a handle for lifting as it may break off. Rather, grip the sides of the door for lifting.

The procedure for replacing the door is as follows:

1. Check that no wiring is going to be crushed when the door is re-fitted.

2. Check that the key lock is in the unlocked position.

3. Angle the top of the door towards you as you slide the bottom lip of the door into the master post.

4. Tilt the door up towards the vertical position until it hits a stop (at about 20º to the vertical).

5. Lift the door up slightly to clear the stop and continue to tilt the door up until it is flush with the back of the master post. Be sure the bottom lip of the door does not disengage from the post.

6. Let the door drop downwards to allow the locking hooks on the door to engage with the slots in the master post.

7. Turn the key to lock the door. Remove the key and retain in a secure place.


41

6.3 Pull-in Cable Replacement

If an excessive load is applied to the Pull-in Cable while the Gate is open or in the process of closing, the Pull-in Cable may break.

WARNING

A worn or broken Pull-in Cable may have very small broken fibres that will cut skin if handled. You should always use gloves when handling a used Pull-in Cable.

6.3.1 To remove a worn or broken Pull-in Cable...

1. Unlock and remove the door on the back of the Master Post.

2. Open the gate (using appropriate access control means) and disconnect the motor cable connector to prevent accidental operation of the Gate and the risk of injury.

3. Disconnect the Pull-in Cable from the winch drum.

(i) Push down (ii) Lift up

(iii) Pull back

4. Disconnect the Pull-in Cable from the Main Cable End by pushing the large ball on the end of the pull-in cable out of its hole and pull the rest of the pull-in cable through the cable end. (Twist the pull-in cable to encourage ball to come out of its hole.)


42

6.3.2 To install a new Pull-in Cable...

1. Insert the small ball on the end of the pull-in cable into the hole on the side of the cable end and poke it out the front of the cable end.

2. Continue to pull the pull-in cable through the cable end until the large ball seats inside the large hole in the cable end.

3. Insert the small ball end of the Pull-in Cable through the hole at the back of the entry mouth.


43

4. Feed the Pull-in Cable down through the hole on the top of the guide pulley and attach to the winch drum.

(i) Feed ball end down through hole in Guide Pulley Cover

(ii) Feed Cable through hole (iii) Push down into groove (iv) Pull back to lock in place and rotate drum to take up

slack in pull-in cable

5. (i) Reconnect the Motor Cable Connector.

(ii)Press the Clear Faults (“CF”) button on the Gate Controller. The Motor will run for 2 seconds.

(iii)Finally, press the “F1” button on the Gate controller. The Gate will now be in an “open” state.

6. Test the operation of the Gate by opening and closing it a number of times.

7. Replace and lock the door on the rear of the Master Post.


44

6.4 Entry mouth assembly replacement

WARNING

The pull-in cable may have very small broken fibers that will cut skin if handled. Do not handle the pull-in cable with bare hands.

The entry mouth may be removed using the following procedure:

1. Open the gate and lock it down, either by using the over ride switch (if fitted), covering over the photoelectric safety beam or by disconnecting the motor connector inside the master post. Note that covering over the safety beam may not hold the gate down permanently, depending on the value of the parameter set in section 4.5.10 above.

CAUTION

Do not use adhesive tape to block off the PE beam as residue from the tape may

attract dust to the PE window. This may cause subsequent failure of the PE beam.

2. Detach the pull-in cable from the winch drum and remove it from the entry mouth using the procedure detailed in section 6.3.1 above.

3. Undo all the screws on the entry mouth using suitable tools. Leave the upper central screw till last and be ready to support the weight of the entry mouth as this final screw comes loose. Care should be taken to ensure a secure handgrip on the entry mouth during removal since the component weighs about 2kg.

4. Move the entry mouth away from the master post until it is clear of the pull-in cable.

The entry mouth may be re-attached using the following procedure:

1. Thread the pull-in cable through the entry mouth and insert the upper central screw through the entry mouth and tighten 3-4 turns.

2. The entry mouth is retained by a total of five (5) screws. Three (3) of these are high strength (grade 12.9) socket head cap screws and two (2) are low strength security screws. It is important that the screws are placed in the correct holes (as shown in Figure 6-2 below) to achieve maximum security and strength.

3. Insert the other screws into their holes and tighten. Take care not to over tighten the security screws as the heads of these screws can easily be sheared off. Conversely, the socket head cap screws can be tightened very firmly.

4. Reinsert the pull-in cable into the entry mouth and fit it to the winch drum using the procedure outlined in section 6.3.2 above.

5. Press the clear faults (“CF”) button and then the “F1” button on the control board inside the master post (if required) and restore the gate to normal operating mode.


45

Figure 6-2: Front view of Entry Mouth showing location/type of screws

Cap Screw

Cap Screw

Cap Screw

Security Screw Security Screw


46

6.5 Main Operating Module (MOM) removal/replacement

The MOM will need to be removed from the master post if the latch assembly or drive assembly is to be removed.

WARNING

The main operating module is heavy and awkward to lift, weighing approximately 15kg. Wherever possible, two people should be used to lift the module in and out of

the master post.

To remove the main operating module the following procedure should be followed:

1. Detach the pull-in cable from the cable end, as detailed in section 6.3.1 above.

2. Open the door in the back of the master post. Disconnect the motor connector.

3. Wind the winch drum by hand until the pull-in cable is pulled all the way up inside the housing (until the winch drum can’t be turned any more).

4. Undo the security screws holding the post cap to the post. Remove the post cap and, if beacons are fitted, disconnect the beacon connecter. The connector is in the folded top part of the spine. Disconnect the antenna connector.

5. If any access control systems, apart from key fob, are installed these will need to be disconnected. This may involve opening the electronics enclosure and removing the long multi way connectors or detaching other connectors.

6. Disconnect the battery connector, found just below the electronics enclosure.

7. Remove the entry mouth, as detailed in section 6.4 above.

8. Remove the two screws that are located low down on the front of the master post.

9. Checking that no wires are going to be pinched or pulled, lift the main operating module up vertically, using the handle provided at the top. The module can then be placed horizontally on a work surface for inspection/repair.


47

To re-install the main operating module (MOM) the following procedure should be used:

1. Checking that no wires are going to be pinched upon installing the MOM, lower the MOM vertically into the top of the master post, using the handle provided at the top of the MOM. Be careful not to pinch fingers between the post and any part of the MOM.

2. Insert the two lower screws on the front face of the post and turn 3-4 times. In order for the two holes in the master post to line up with the tapped holes in the spine it may be necessary to lift the MOM slightly (approximately 1 mm).

3. Align the MOM so that the large holes in the spine and in the master post are concentric. When this is achieved, tighten the two lower screws on the front face of the master post.

4. Reconnect the entry mouth to the front of the master post as detailed in section 6.4 above.

5. Reconnect the cable end to the pull-in cable as detailed in section 6.3.2 above.

6. Reconnect the beacon wiring harness (if fitted) and antenna wiring harness (if fitted) before refitting the post cap and tightening all four screws.

7. Reconnect the battery and all other electrical wiring and components.

8. Check that the gate operates correctly.

9. Replace the rear door on the master post (see Section 6.2 above).


48

6.6 Motor drive assembly replacement

To remove the motor drive assembly the following procedure should be followed:

1. Remove the main operating module (MOM) from the master post as detailed in section 6.5.

2. Disconnect the motor connector and clutch connector.

3. Disconnect the pull-in cable from the winch drum as detailed in section 6.3.1 above.

4. Using a small flat bladed screwdriver, remove the spring clip on the socket joint that connects the latch release rod (threaded rod) to the latch release disc on the drive shaft. Remove the spring clip by pulling it along the axis of the rod with a pair of needle nosed pliers.

5. Lever the socket joint at the end of the latch release rod away from the ball on the latch release disc.

6. Undo the four (4) countersunk screws and nuts holding the drive assembly support plates to the spine bracket.

7. Remove the motor drive assembly from the spine bracket.

To re-install a new motor drive assembly the following procedure should be followed:

1. Fasten the motor drive assembly to the spine with the four screws, nuts, and washers. Tighten the nuts firmly.

2. Press the socket joint at the end of the latch release rod onto the ball on the latch release disc. Firm pressure is needed to achieve this.

CAUTION

The latch release disc can only rotate in one direction. Be very careful not to turn the

latch release disc so that the latch release rod cannot reach it. If this occurs it is possible to force the latch release disc to turn the wrong way, or to apply a voltage to

the motor to make it turn back.

3. Using needle nosed pliers, insert the spring clip into the hole in the socket end and push it down to lock around the socket end.

4. Reconnect the pull-in cable to the winch drum, as specified in Section 6.3.2 above.

5. Reconnect the motor and clutch connectors.

6. Reinstall the MOM into the master post, as specified in Section 6.5 above.


49

6.7 Latch housing assembly replacement

If it is required to remove the latch and latch housing for any reason then the following procedure should be followed:

1. Remove the main operating module (MOM) from the master post, as detailed in section 6.5 above.

2. Detach the latch release rod from the latch, either by removing the nut holding the ball to the latch, or by removing the spring clip on the socket joint and popping the socket off the ball.

3. Undo the brass screws on the lock microswitch and remove the black and yellow wires.

4. Disconnect the connector that connects the PE beam to the wiring harness.

5. Undo the four countersunk screws holding the latch housing to the spine.

6. Remove the latch housing from the main operating module (with the folded bracket and photoelectric (PE) beam attached). If further disassembly is required then undo screws to remove the switches or the PE beam unit. To remove the latch, remove the spring and let the latch fall out. Some twisting of the latch may be necessary to remove it from the housing. Be careful of any grease on the latch and latch housing as it may stain clothing or skin.

To re-install the latch housing assembly into the main operating module, the following procedure should be followed:

1. If the latch housing, latch, spring, microswitches, PE bracket and PE unit are not already assembled together then do so at this point. To assemble the switches, PE bracket or PE unit, simply tighten the relevant screws. The switches should be oriented so that the roller points towards the flat surface on the housing, which will mount flush with the spine. The PE unit sits on top of the bracket with the LED’s at the top of the PE unit facing away from the latch housing. These correct orientations can be seen in Figure 2-4. The section where the latch rubs on the latch housing needs to be greased. If sufficient grease is not present in the region, or if a new latch is being installed then grease will need to be applied.

CAUTION

If the grease to be applied is of a different type to the existing lithium based grease, then all existing grease should be removed with a hydrocarbon based solvent before

the new grease can be applied. Mixing different types of grease can cause a breakdown of the lubrication properties of the grease.

2. Place the latch housing into its correct position on the spine.

3. Insert and tighten the four countersunk screws that attach the latch housing to the spine.

4. Connect the lock microswitch to the correct yellow and black wires on the wiring harness. The yellow wire connects to the terminal marked “COM” and the black wire connects to the terminal marked “NO”. Ensure the screws are done up firmly.

5. Reattach the latch release rod to the latch by either popping the socket over the ball and replacing the spring clip or by inserting the screwed section on the ball into the hole in the latch and tightening the nut with spring washer as appropriate.


50

6. Replace the MOM into the master post, as detailed in section 6.5 above.

7. If the PE beam bracket was removed this should be re-aligned using the procedure outlined in Section 6.10.7.1 below.

6.8 Main cable assembly replacement

In order to remove the main cable from the Cable Gate, the following procedure should be used:

1. If the main cable is to be refitted later, mark the point at which the cable enters the counterweight bar. This can be achieved using a fine oil marker on the cable against the entry point to the counterweight bar

2. Using a “system 0” driver (available from Access Technologies (WA) Technologies), undo the security screws underneath the counterweight bar that hold the security plate (if fitted) to the counterweight bar.

3. Undo the screws that clamp the wire rope grips onto the main cable. These screws are accessed from beneath the counterweight bar and should be progressively loosened a small amount at a time. Be careful of the counterweight bar dropping down as the final screws are released and the main cable slides out of the counterweight bar.

4. Open the gate and lock it down by either using the over ride switch or disconnecting the motor inside the master post.

5. Remove the cable end from the pull-in cable, as detailed in Section 6.3.1 above.

More detailed instructions on installing a new cable can be found in the Cable Gate Installation Manual. In order to install a new or used main cable to the Cable Gate, the following procedure should be used:

1. Check that a cable ferrule has been installed onto the main cable near the cable end. If a ferrule has not been fitted, attach one to the main cable at the point indicated in the Cable Gate Installation Manual (approximately 1 metre from the cable end).

2. Thread the main cable through the sheathing and install the “P-retainer” onto the sheathing (to stop the sheathing sliding over the ferrule).

3. Depending on whether the main cable to be installed is new or used follow the steps below:

a. For a new main cable – Attach the cable end to the pull-in cable and allow the Cable Gate to close and lock. Holding the counterweight bar horizontal, pull on the main cable until the cable is 500mm off the ground at its lowest point. Mark the point at which the main cable needs to be cut off so that it will fit into the counterweight bar. Cut off the main cable at this point. Open the Cable Gate and ensure that it stays open. Insert the bare end of the main cable into the counterweight bar. Note also that this procedure is covered in additional detail in the Cable Gate Installation Manual.

b. For a previously used main cable – Insert the bare end of the main cable into the counterweight bar, up to the mark that was previously made on the main cable.

4. Moderately tighten the screws that clamp the wire rope grips onto the main cable.

5. Close the Cable Gate and check that the minimum height of the main cable above


51

the ground at the centre is 500±25mm. Adjust the main cable in the counterweight bar if required.

6. Once the correct height of the main cable has been achieved, progressively tighten the screws in a zigzag pattern, working from front to rear on the counterweight bar. This zigzag pattern will need to be repeated several times as each time you tighten one screw the screws either side will become loose. The screws should be tightened firmly with a long handled Allen key and the heads of the screws should not protrude below the lower surface of the counterweight bar.

7. Restore the gate to normal operating mode and check for correct operation.


52

6.9 Counterweight bar assembly replacement

In order to remove the counterweight bar assembly the following procedure should be followed:

WARNING

Ensure that the Cable Gate cannot be inadvertently opened while the Counterweight Bar is being removed, as the falling Counterweight Bar may cause injury. The

recommended method of doing this is to disconnect the Motor Connector inside the Master Post.

1. Mark the point where the Main Cable enters the Counterweight Bar and disconnect the Counterweight Bar from the Main Cable, as detailed in Section 6.8 above.

2. Remove the Passive Post Cap.

3. Undo the Locking Screw in the Counterweight Bar Pin (shown in Figure 6-3 below) and remove it from the pin.

Figure 6-3: Counterweight Bar Pin and Locking Screw

4. Support the Counterweight Bar with one hand and slide the pin out of its housing. Remove the Counterweight Bar.

WARNING

Do not insert fingers through the hole in the counterweight bar support bracket, as they will be crushed if the counterweight bar falls. Instead pull the pin through from

the outside.

Counterweight Bar

Locking Screw

Pin

Counterweight Bar Support

Bracket


53

In order the replace/install the counterweight bar the following procedure should be followed:

1. Pass the end of the counterweight bar with a hole in it into the passive post and insert the pin through the holes in the counterweight bar support bracket and counterweight bar.

2. Tighten the locking screw all the way into the counterweight bar pin, as shown in Figure 6-3 above.

3. Replace the passive post cap.

4. Reconnect the main cable to the counterweight bar, as detailed in section 6.8 above.

6.10 Electrical Repairs

6.10.1 Clearing Fault Indications

When the Cable Gate experiences the same fault a number of times within one cycle, the gate will stop operating and a fault number will be displayed on the seven segment diagnostic display. The diagnostic display can be viewed through the Perspex window in the back of the master post. Once the problem causing the fault has been identified and fixed, the fault needs to be cleared before the gate will operate correctly again.

To clear a fault the following procedure should be used:

1. Open the door in the back of the master post and undo the four screws, which attach the clear plastic lid to the electronics enclosure.

2. Press the clear faults button (labelled “CF”) on the main control board as shown in Figure 2-6 above. Do not press the reset button (labelled “RES”) as this resets the entire controller, possible leading to a loss of data in the microprocessor. The diagnostic display will flash a number of times before the gate resumes its normal operating mode.

3. Press the button labelled “F1” to run the gate through a cycle and check its operation. Run the gate through a number of cycles to confirm that it is operating correctly.

4. Reattach the lid on the electronics enclosure and do up the four screws. Reattach the door on the back of the master post.

6.10.2 Electronic control module replacement

If the electronic control module needs to be replaced then the following procedure should be followed:

1. Turn off the external power supply to the Cable Gate.

2. Open the door in the back of the master post.

3. Detach the motor connector, battery connector, clutch connector, and photoelectric (PE) beam connector.

4. Open the lid of the electronics enclosure.

5. Undo the antenna connection and the support screw on the radio receiver board and remove the radio receiver board from the header on the control board (if fitted).

6. Detach the connector for the main operating module (MOM) wiring harness from the control board and remove the rubber grommet from its slot in the electronics enclosure. Refer to Figure 2-6 above for the location of this connector.

7. Detach the 12-way connector and 6-way connector from the control board. Remove the grommet from its slot in the electronics enclosure. Refer to Figure 2-6 above for the locations of these connectors.


54

8. Loosen the lower two screws holding the electronics enclosure support plate onto the spine. Do not completely remove these screws at this time.

9. Remove the upper two screws holding the electronics enclosure support plate onto the spine.

10. Slide the electronics enclosure upwards (to clear the lower two screws) and remove from the MOM.

11. Depending on the method used to fix the electronics enclosure then:

a. If the enclosure is screwed in place then ... undo the top screws and loosen the bottom screws holding the enclosure support plate to the spine and remove the enclosure.

b. If the enclosure is taped in place then ... use a screwdriver or fingers to prise the left hand side of the enclosure away from the post, tearing the double-sided tape holding it in place.

To install a new control board the following procedure should be followed:

1. Depending on the method of fastening the enclosure in place then:

a. If the enclosure is screwed in place then ... fit the electronics enclosure onto the spine. The two lower attachment screws should already be in the spine. Slide the electronics enclosure support plate down onto these lower screws and attach the two upper screws. Note that P-clips for the MOM wiring harness may also used the two upper screws. Tighten all four screws.

b. If the enclosure is taped in place then ... clean any old double-sided tape from the back of the enclosure or from the inside of the post. Apply new double-sided tape to the back of the electronics enclosure and stick it in place on the post. Apply pressure to hold the enclosure to the post for 1 minute to ensure sufficient bond strength develops.

2. Attach the 12-way connector, 6-way connector, radio receiver (if fitted), antenna (if fitted) and MOM wiring harness connector to the control board and insert the appropriate grommets in their respective slots in the electronics enclosure. Ensure the grommets are all well seated.

3. Attach the PE beam, motor and clutch connectors.

4. Attach the battery connector, keeping fingers well clear of any moving parts.

5. Press one of the fob buttons on the control board (labelled “F1” & “F2”) to cycle the gate and check its operation.

6. Turn on the external power supply to the Cable Gate and check that the external supply (“ES”) LED on the control board is illuminated.

7. Close the lid of the electronics enclosure.

8. Replace the door on the back of the master post.


55

6.10.3 Main Operating Module (MOM) wiring harness assembly replacement

If the entire wiring harness is to be replaced, it should first be double-checked that the new wiring harness is compatible with the existing wiring harness.

To remove the old wiring harness the following procedure should be followed:

1. Open the door in the back of the master post.


3. Note the layout of the wiring harness and the location of each termination. Although the wiring harness has been designed to prevent incorrect re-connection, it is advisable to mark each connector prior to disassembly.

4. Disconnect the clutch, photoelectric (PE) unit and beacons (if fitted). Remove the bulkhead connector for the beacons by pressing together the two arms on the side of the connector and pushing it down through the top of the spine.

5. Detach the ring connectors from the lock microswitch.

6. Remove the two screws from the top of the electronics enclosure support bracket to allow the wires to be extracted from the P-clips at these locations. Replace the first screw before removing the second screw, to prevent the electronics enclosure falling off the spine.

7. Take the lid off the electronics enclosure and remove the MOM wiring harness connector from the control board. Refer to Figure 2-6 above for the location of this connector. Slide the appropriate grommet out of its slot in the electronics enclosure.

To install the new wiring harness the following procedure should be followed:

1. Fit the multi way connector on the end of the MOM wiring harness to the control board.

2. Seat the grommet in the appropriate slot in the side of the control board.

3. Pass the harness through the P-clips at the top of the electronics enclosure support plate and fix the P-clips with the same screws that go through the top of the electronics enclosure support plate.

4. Attach the ring connectors to the lock microswitch and tighten the brass screws firmly. Refer to Figure 2-4 above for the correct attachment of the wires to the microswitches.

5. Push the bulkhead connector for the beacons up through the hole in the top of the spine plate.

6. Connect the clutch, PE unit and beacons (if fitted) to the harness.

7. Attach the motor connector, press the clear faults (“CF”) button and check that the gate operates correctly.

8. Fit the lid to the electronics enclosure.

9. Replace the door on the rear of the master post.


56

6.10.4 Battery Replacement

In order to replace the batteries the following procedure should be followed:

1. Open the door in the rear of the master post.

2. Disconnect the motor connector to prevent inadvertent activation of the gate.

3. Disconnect the leads from the batteries, noting the orientation of the batteries and the position of the various leads.

4. Remove the old batteries and place the new batteries inside the master post. Note that the correct terminal orientation for the batteries is indicated on the battery tray located at the base of the master post.

5. Connect the leads to the batteries. The red lead goes on the positive terminal of the furthest battery. The short link lead goes between the two batteries. The black lead goes on the negative terminal of the closest battery. Refer to Figure 2-7 to confirm the correct battery wiring.

6. Reconnect the motor connector.

7. Check for correct operation of the gate and replace the door on the back of the master post.

6.10.5 Main Control Board fuse Replacement

There are five fuses on the main control board. Three of these fuses (battery, access control and solar) can be seen in Figure 2-6 above. The locations of the remaining two fuses (clutch and beacon) can be seen on the silkscreen diagram in Appendix A.

Before replacing a fuse for the first time, always search for an obvious reason as to why the fuse has blown. If the first replacement fuse blows as well, a thorough check of the relevant circuitry and wiring harness should be carried out before replacing the fuse for a second time.

In order to remove and replace a fuse the following procedure should be followed:

1. Remove the door from the back of the master post and disconnect the batteries and any external power supply.

2. Open the clear plastic lid on the electronics enclosure and remove the fuse using the special fuse removal tool. The hooks on either end of the tool should hook under the metal ends of the fuse, not around the glass section. In order to gain access to the clutch or beacon fuse, the long 12-way screw connector will need to be temporarily removed. If a fuse removal tool is not available then needle nose pliers may be used, but with extreme care, once again gripping the metal ends rather than the glass section of the fuse.

3. Ensure the new fuse is of the same dimensions and current rating as the old fuse.

4. Insert the new fuse into the holder, making sure that it seats correctly against the fuse holder.

5. Reconnect the batteries and observe whether the fuse blows again or not. If the fuse blows again then the root cause of the failure should be located.

6. Reconnect the external power supply and again check that the fuse does not blow.

7. Reattach the lid on the electronics enclosure.

8. Run the gate for a number of cycles to check for correct performance.

9. Reattach the door on the back of the master post.


57

6.10.6 Lock Microswitch Replacement

It is possible to replace the lock microswitch while the main operating module (MOM) is still inside the master post, but it may be easier to do so after the MOM has been removed from the master post. To replace the lock microswitch the following procedure should be followed:

1. Remove the back door from the master post.

WARNING

Disconnect the motor connector while the gate is locked. The Cable Gate needs to be disabled as inadvertent operation poses a crushing hazard to any fingers near moving

parts

2. Detach the two ring connectors from the lock microswitch by undoing the brass screws on the lock microswitch. Take note of the terminals on the microswitch that the coloured wires connect to prior to removal.

3. Undo the lower attachment screw on the lock microswitch. Doing this will involve inserting the screwdriver through the coils of the latch spring. The latch spring may be removed to facilitate easier access, but be aware that the latch will fall down and be difficult to move back up (because of the one way bearing on the drive assembly) if not supported.

4. Push the latch down to give access to the lower attachment screw and remove this last screw from the lock microswitch.

5. Remove the old lock microswitch, noting its orientation.

6. Position the new lock microswitch and fasten the lower attachment screw.

7. Move the latch upwards to provide access to the upper attachment screw. Moving the latch upwards will require some force as this causes the entire motor to turn backwards.

8. Tighten the upper attachment screw and check that both screws are fastened firmly. Screws should not be over tightened as this may break the switch.

9. Attach the two ring connectors to the new lock microswitch; ensuring the coloured wires are connected to the correct terminals (refer Figure 2-4).

10. Reattach the motor connector; press the clear faults (“CF”) button on the control board, keeping fingers well clear of any moving parts.

11. Cycle the Cable Gate a number of times to check correct operation.


58

6.10.7 Replacement of Photoelectric (PE) unit

The PE unit is located within the master post, directly above the electronics enclosure. To replace the PE unit the following procedure should be followed:

1. Open the door in the back of the master post and remove the access cover on the side of the master post.


3. Detach the old PE unit connector.

4. Note the alignment of the old PE unit on its mounting bracket.

5. Undo the screws holding the old PE unit to the bracket and remove the unit.

6. Ensure the new PE unit has the same settings as the old unit being removed. Setting switches are found under the top cover of the PE unit.

7. Place the new PE unit on the mounting bracket (in the same alignment as the old unit) and attach the screws.

8. Align the PE unit. Refer to section 6.10.7.1 below.

9. Reattach the motor connector and press the clear faults (“CF”) button on the control board.

10. Close the door in the back of the master post and attach the access cover to the side of the master post.

11. Complete several operating cycles on the gate to check for correct operation.

6.10.7.1 Aligning the Photoelectric (PE) unit

WARNING

In the course of aligning the PE unit, it may be necessary to have the motor connected while adjustments are being made to the PE unit. Take extreme care not to place any part of your body near any parts that may start/stop moving as the PE beam

is made or broken.


59

Accurate alignment of the PE unit is essential to correct operation of the Cable Gate. A PE unit that is not exactly aligned will fail to perform in bad weather or dusty conditions. In order to exactly align the PE unit with the reflectors in the passive post the following procedure should be followed:

1. Open the Cable Gate and move the office box switch (if fitted) to the down position. If the office box switch is not fitted then pins 6 and 9 on the green 12 way (X2) connector can be wired together to achieve the same effect. Note that the Cable Gate needs to be open for power to be supplied to the PE unit. Rotate the PE unit until the beam is made and nip the horizontal adjustment screws tight (refer Figure 2-4 above). This shows the PE unit is close to the correct alignment. There are a number of ways to determine if the beam is made or broken, such as:

a. If the override switch is in the “down” position and beacons are fitted, the beacons will flash green when the beam is made and red when the beam is broken.

b. If the Cable Gate is open, the LED on the control board marked “PE” will be blank if the beam is made and illuminated when the beam is broken. Note that the LED is set-up so that it will always illuminate for at least 0.5 seconds even if the beam is only momentarily broken.

c. On the side of the PE unit are two LEDs. These can be seen through the access panel in the side of the master post. The orange LED indicates when the PE beam is made or broken.

2. Cover the reflectors in the passive post so they are not visible from the PE unit.

3. Taking a hand held reflector and standing at the passive post, move the reflector left and right in front of the post to determine the vertical centreline of the PE beam. Unless the Gate is fitted with beacons and an over ride switch, two people will be needed to undertake this operation. To find the centreline first move the reflector leftwards until the beam is broken (note the position of the reflector), then move the reflector rightwards back through the beam until the beam is broken again (note the position of the reflector). The midpoint between the two noted positions is the centre of the beam.

4. Very carefully loosen the horizontal adjustment screws and adjust the angle of the PE unit before tightening the screws. Repeat the previous step until the centre of the beam is within ±40mm of the centre of the reflectors on the passive post.

5. Check the vertical alignment of the PE unit, using the procedure specified above, by moving the hand held reflector up and down with the passive post reflector covered. Adjust the vertical angle of the PE unit if required. The vertical adjustment screws for the PE unit are shown in Figure 2-4 above.

6. Restore the over ride switch to the neutral/auto position (if used) and check the Cable Gate operates correctly.

7. Refit the rear door and side cover on the master post.


60

Appendix A: Control Board Schematics


61

A.1 Controller Silkscreen

Beacon Fuse

Clutch Fuse

Solar Panel Fuse7 Segment Displays

Rotary Switch


62

A.2 Cable Gate Controller Block Diagram

DC

AC

BatteryCharger

M

Clutch driver

Motor Driver

Beakon drivers

GateLockeddrivers

SensorPowerSwitch

24 to 12VConverter

Microprocessor

Up

Down

Exit Road Loop

Safety

Entry Road Loop

Lock

Clear Faults

Spare (MK2 Open)

Solar

Cable Gate MK3 Controller

RF Key FOB Receiver

Red Beakon

Green Beakon

Clutch

Motor

Access Control Power(500 mA)

Sensor Power (200 mA)

Gate Output 1

Gate Output 2

12 V 7Amp/hr SLA

12 V 7Amp/hr SLA

10 Position Rotary Switch

Beacon drivers

Red Beacon

Green Beacon


63


64

Appendix B: Australian Average Annual Median Temperature


65


66

Appendix C: Battery Installation, Commissioning and Maintenance Guide


67

(The following information is adapted from the Yuasa manual for NP batteries)

Storage

If the batteries are not to be installed immediately, keep them boxed and store in a cool, clean and dry place.

If the batteries are to be stored for six months of more they will need a supplementary charge prior to installation as outlined below.

Unpacking and Inspection

WARNING

Batteries are electrically live at all times. Do not short-circuit the battery terminals.

Under no circumstances should batteries be charged in a sealed container.

Inspect the battery consignment for obvious signs of transit damage. Ensure the consignment has all items listed on the advise note or invoice, i.e. batteries, cables, shrouds etc.

Unpack each battery taking care not to drop on the terminals. Inspect each battery for physical damage such as cracks or distortion of the case and terminals.

Measure the battery open circuit terminal voltage, which should be 2.1 volts/cell (12.6 volts for a 6 cell battery). If any batteries are lower they will need a supplementary charge prior to installation.

Supplementary Charge

To ensure maximum service life, a supplementary charge may be required prior to installation. Apply a supplementary charge if:

• The batteries have been in storage 6 months of more.

• The battery open circuit voltage is under 2.1 volts per cell.

A supplementary charge should be applied in accordance with figures shown in the table below.

Table C.6-1: Supplementary Charge for the Yuasa NP Battery (can also be used for Century PS

batteries)

Storage Period Charge Voltage (for 12V battery)

Charge Time

Not more than 1 year 13.62V More than 3 days

1 year 14.1V 2-6 days

1-2 years 13.68V 3-6 days

After the charge period, check that the battery open circuit voltage is above 2.1 volts/cell.


68

Pre Installation Check List

The batteries should be installed in a dry and adequately ventilated area with an operational temperature of between 20ºC and 25ºC.

Installation and Connection

A wire brush should be used on all battery terminals to remove any oxidation layers. Application of non-oxidising grease (such as Vaseline) is not necessary. However there may be some installations where there are corrosive compounds/elements nearby or in the atmosphere. In these special cases it is recommended that non-oxidising grease be used.

When installing batteries remove any jewellery and watches.

When installing the batteries, free air space must be provided between each battery. The recommended distance is 10mm minimum.

Since a battery may generate ignitable gases, do not install close to any items that produce sparks.

The battery case is made from ABS resin. Do not, therefore, place is an atmosphere with organic solvents or adhesive material.

Single String Battery Connection

When multiple numbers of batteries are used, make connections as follows:

Positive Termination: Connect the positive terminal (+) of battery No1 securely to the positive terminal (+) of the charge/load.

Intercell connections: Connect the negative terminal (-) of battery No1 to the positive terminal (+) of battery No 2.

Negative terminal: Connect the negative terminal (-) of the final battery securely to the negative terminal (-) of the charger or load.


69


70

Appendix D: Battery Product Safety Data Sheet


71

(This Product Safety Data Sheet is take from the Yuasa PSDS May 02)

Prepared following the Guidelines in Appendix 1 of the HSE publication L62 0 Guidance on regulation 6 of the Chemicals (Hazard Information and Packaging) Regulations 1994

Product Identification

Name: Valve Regulated Lead Acid (VRLA) Battery.

Classification: Batteries, wet, non-spillable, electric storage. Substance identification No. UN 2800

Manufacturer’s Name & Address Century Yuasa Batteries 49-65 Cobalt Street Carole Park, Qld PO Box 427 Goodna QLD 4300 Tel: (07) 3361 6161 Fax: (07) 3361 6166

Composition

Component Approx. by weight or volume

Air Exposure Limits (mg/m3) O.E.L.

Lead and lead alloy metals 35% N/A

Lead inorganic compounds 40% 0.15 mg/m3 as dust in air

Electrolyte – Sulphuric Acid (up to 40% w/w)

15% 1 mg.m3 as mist in air

Separator – Glass Fibre 2%

Hazards Identification Sulphuric Acid (up to 40% wlw)

Severe IRRITATION and DAMAGE to internal tissues if swallowed, causes IRRlTATION of eyes and skin and may cause BURNS and DERMATITIS R35% Causes severe burns (15% & above) No specific antidotal treatment, symptomatic support required. No known delayed effects after single exposure apart from Consequences of local tissue damage.

Lead inorganic compounds TOXIC by ingestion or inhalation of dust, vapour or fume. R61 May cause harm to the unborn child R20/22% Harmful by inhalation and if swallowed R33% Danger of cumulative effects

Glass mat separator Fibres may cause IRRITATION to skin or eyes upon exposure and to Internal tissues if inhaled or swallowed.


72

First Aid Measures

Inhalation Sulphuric Acid: If mist is inhaled, remove from exposure and to fresh air

immediately. If there are any breathing difficulties take to hospital.

Lead: Remove from exposure, wash out mouth and wash. Glass Fibres: If fibres have been inhaled, remove to fresh air. If irritation persists

Take to hospital.

Exposure of Eyes Sulphuric Acid: Wash out immediately with copious amounts of water for at least

15 Minutes, holding the eye open if necessary. Take to hospital. Lead Compounds:

Wash out immediately with copious amounts of water for at least 15 minutes holding the eye open if necessary. Take to hospital.

Exposure of Skin Sulphuric Acid: Wash off skin immediately with copious amounts of water for at

least 15 minutes. Remove all contaminated clothing, which must be Washed thoroughly before re-use. Remove and dispose of contaminated Footwear.

Lead Compounds:

Wash off skin thoroughly with soap and water.

Fire Fighting Measures

Batteries on charge may emit hydrogen gas that is highly flammable and will form explosive mixtures in air from 4% to 76% concentration. This may be ignited by a spark at any voltage, especially form the batteries themselves.

Batteries on charge must be isolated from power source before attempting to put out a fire. Switch off the power before disconnecting the batteries from the power source.

Batteries in use will be part of an electrical circuit and so water must never be used to put out afire.

Damaged batteries may expose negative plates (grey colour) that may ignite if allowed to dry out. These plates should be wetted down with water after the battery has been removed from all electrical circuits.

Use extinguisher types: CO2, Dry Powder

Hazardous decomposition products: Carbon monoxide, sulphur dioxide, sulphur trioxide, lead Fume and vapour, toxic fumes from decomposition of battery case materials.

Special precautions: Use self-contained breathing apparatus and full acid resistant protective clothing.


73

Accidental Release Measures

These batteries are designed not to leak under normal conditions. If, however, electrolyte does leak out of any battery for any reason, it should be absorbed onto dry sand, earth or other inert material and must not be allowed to enter any drains. If possible, neutralize any leaked electrolyte using soda ash, sodium bicarbonate, sodium carbonate or calcium carbonate powder and then wash thoroughly with water. Collect absorbed material, and place in an inert sealed container for disposal

Handling and Storage

Store batteries in a cool and dry area with an impervious surface. Store under roof and protect against adverse weather conditions. Protect against physical damage and exposure to organic solvents. Do not allow metal objects to contact both terminals at the same time. This will cause damage, sparking and possible injury.

Large batteries should be handled and moved using mechanical means to prevent risk of injury.

Exposure Controls / Personal Protection

Under normal conditions, where there is no damage and no visible trace of liquid or solid deposit on the batteries, they may be handled without any additional P.P.E. Where there are any signs of damage or liquid or solid deposits, rubber gloves and acid resistant clothing must be worn when handling the batteries and affected packaging to protect against the effects of any acid electrolyte that may be present. If it is suspected that free acid electrolyte is present, then safety glasses must be worn. If large amounts are present, chemical goggles or face shield should be used.

Physical and Chemical Properties

The undamaged product is a manufactured item in an inert plastic case, which will burn if subjected to high temperatures. Some battery types are made in flame retardant plastic, see technical specification.

Batteries on charge may emit hydrogen gas, which is highly flammable and forms explosive mixtures in air.

Electrolyte is a clear liquid with little or no smell. It comprises water and up to 40% sulphuric acid. Leaked electrolyte may dry out to form white patches or patches of other colours, usually green or brown if metals have been attacked, which may be acidic.

In damaged batteries, lead plates can be grey or brown with varying amounts of white. Grey material may ignite if left to dry out.

Stability and Reactivity

The undamaged product is stable up to 60ºC.

Toxicological Information

Sulphuric Acid: LD50 2140mg/kg oral, rat LC50 0.51 mg/L inh rat

Lead compounds: No specific data


74

Ecological Information

Sulphuric Acid: Toxic to fish and algae.

Concentrations of 100% sulphuric acid greater than 1.2mg/L may be lethal to fish. Lowering pH below about 5 would induce fatalities in aquatic life.

Lead compounds: No specific data.

Disposal Information

UNDAMAGED & DAMGED BATTERIES Store in impervious inert container and send to smelter for recycling. Must be treated as special waste, therefore contact supplier for assistance.

ABSORBED SPILLED ELECTROLYTE Place in sealed inert container. Treat as special waste. Contact supplier for assistance.

Transport Information

VRLA batteries, supplied by Yuasa Battery Sales (UK) Ltd are exempt from requirements of:

Dangerous Goods Regulations, 30th Ed., effective from 01.01.96, because they meet ICAO Special Provision A67 as Class 8., Group111, UN No.2800, Batteries, wet, non-spillable, electric storage.

International Maritime Dangerous Goods (IMDG) Code Amendment 27-94, which incorporates the ICAO special Provision A67, for any special conditions. Other relevant general conditions apply.

European Agreement concerning the International Carriage of Dangerous Goods by Road (ADR).

Regulatory Information

Batteries supplied by Yuasa Battery Sales (UK) Ltd are subject to The Batteries and Accumulators (containing Dangerous Substances) Regulations 1994 and are marked in accordance with the requirements of Regulation4.

Other Information

To ensure safe use of VRLA batteries by Yuasa Battery Sales (UK) Ltd, the following precaution must be observed:

Never install batteries in a gas-tight enclosure as gases may be generated during use.

Batteries must be charged on a voltage-regulated charging system and adequate ventilation provided to avoid the build-up of ignitable gases. Contact your YUASA battery supplier for advice.

Never short-circuit battery terminals as sparks and arcs produced can injure personnel and are a fire hazard.

Do not charge batteries above +50ºC, or discharge or store above +60ºC.

Under extreme conditions of charging equipment malfunctions and/or battery failure, high voltage and high temperature conditions may occur causing the evolution of Hydrogen Sulphide (H2S) gas, which is toxic. If detected by its odour of rotten eggs (at extremely low concentrations), switch off the charging equipment, evacuate all personnel from the area and ventilate well. Seek advice before attempting to re-start charging.


75


76

Appendix E: Accessories and Spare Parts


77

Contact your distributor for information on the access control devices and optional accessories depicted in the following pictures and tables.

Key Fob

Proximity Card

Key Pad

Intercom Road Loop

7-Day Timer

Office Box

Figure E1: Access Control Options


78

• Pole Mounted Traffic

Light (P/N: 99-81-39) • Master Post Beacon

Cap Kit (P/N: 99-81-29)

Combined... • Post mounted solar pole

kit (P/N: 99-81-40) • Post mounted pole &

stop sign (P/N: 99-81-38)

• Solar Panel standalone

pole (P/N: 99-81-33)

• Reflective Cable Flags (P/N: 99-81-36) • 2 way, yellow, raised, glass reflective road markers (P/N: 90-80-03)

Figure E2: Optional Accessories


79

Table E1: Accessories Part Numbers

Description Part

Number SOLAR POWER EQUIPMENT: Solar Panel 21 Watt 94-22-01 Solar Panel mounting pole & bracket, fixed sun setting 99-81-33 Solar Panel mounting bracket, adjustable sun setting 99-81-34 Bolt Cage 20 mm c/w securing nuts & washers 13-65-00 Weatherproof lockable enclosure, 300 x 250 x 150 91-31-08 Post Mounted Solar Pole Kit, adjustable sun setting* 99-81-40 * ONLY suits East-West gate installations VISIBILITY AIDS: Post Mounted Pole Kit & Traffic Light 99-81-39 Post Mounted Pole Kit & STOP sign (single sided) 99-81-38 Master Post Beacon Cap Kit 99-81-29 “Cable Gate” Reflective Flag 13-44-01 “No Entry” Reflective Flag 13-44-02 Hot tape, yellow reflective road striping - 9m roll 90-80-05 2 way, yellow, raised, glass reflective Road Markers 90-80-03 Road Marker adhesive heat pads 90-20-03 OTHER ACCESSORIES: Sheathing Assembly 13-42-00 Weatherproof lockable enclosure, 300 x 250 x 150 91-31-08 Timer, 7 day 94-64-16 Post mounted pole kit, 65 x 35 section (for your signage) 99-81-37 VEHICLE DETECTION ROAD LOOP: Road loop Kit 13-01-19 Road loop Controller, (does not include Base) 94-64-12 RADIO REMOTE KEY FOB: Transmitter Key Fob 94-64-04 Transmitter Batteries 94-21-07 Plug-in Receiver Kit (340 keys) 99-81-25 Hand Held Programmer 94-64-05 Hand Held Programmer Chips 94-64-03 PROXIMITY CARD: "IntelliProx” Smart Module and Microstar Reader 94-64-08 Smart Module (processor) 94-64-06 Microstar Reader 94-64-07 Hand Held Remote Programmer 94-64-09 Proximity Cards 94-64-10 Mounting Post, 1.3 m High 13-90-00 Mounting Post, 2.1 m High - Truck Height 13-90-01 Bolt Cage 12 mm c/w securing nuts & washers 13-66-00


80

Description Part

Number ELECTRONIC KEYPAD: Electronic key pad (non illuminated) 94-64-17 Electronic key pad (illuminated) 94-64-18 Mounting Post, 1.3 m High 13-90-00 Mounting Post, 2.1 m High - Truck Height 13-90-01 Bolt Cage 12 mm c/w securing nuts & washers 13-66-00 INTERCOM SYSTEM: 3 Station Intercom + 2 Speakers 99-81-27 1 Station Intercom + 1 Speaker 99-81-28 Mounting post-1 Station, 1300x100x100mm 99-81-31 Mounting post-3 Station, 2100x100x100mm 99-81-30 Bolt Cage 12 mm c/w securing nuts & washers 13-66-00 OFFICE BOX CONTROL: Office Box, (Down, Auto Mode Switch) 13-01-03

Table E2: Installation Equipment and Spare Parts Part Numbers

Description Part

NumberINSTALLATION EQUIPMENT: Bold Cage 20 mm c/w nuts & washers 13-65-00 Bold Cage Setting – Float Board 13-04-19 Security Nut 20 mm – Shear 13-65-13

Chemical Stud Kit, 16 mm, inc 8 studs, adhesive, spacers 99-81-41

Chemical Anchor Adhesive Applicator Gun 90-40-02 Service Tool Kit 90-40-03 Power Cable, 100m roll 94-74-04 Signal Cable, 200m roll 94-74-06 PE Beam Reflector (double panel) 90-80-01 CONSUMABLE SPARES: Main Cable Assembly 13-41-00 Sheathing Assembly – Normal Duty 13-42-00 Sheathing Assembly – Heavy Duty 99-81-35 Cable Gate Reflective Flag 99-81-36 Pull in Cable – Grubscrew Type 13-17-00 Pull in Cable – Ball to Ball 13-43-00 12v, 7ah, SLA Rechargeable Battery (2 per gate) 94-21-01 Electrical Plug Pack – 24v, 1amp 94-23-01

Documents

Cable Gate MAINTENANCE MANUAL - Access Technologies...1 7, 8 & 10 mm ring/open ended spanners Removing various nuts 1 each Side cutters (in good condition) Trimming end of pull-in